Fully automated, precise sieving and mixing for consistently high powder quality in a closed loop
Our innovative F1 Powder Handling System fully automates powder conditioning, sieving and mixing of new and used powder, helping to ensure consistent part quality, stable processes, and maximum process safety in powder-based polymer 3D printing. The controlled powder conditioning process, using distilled water, establishes a defined moisture level, reduces electrostatic effects, and improves the flow and distribution behavior of the powder. This supports uniform powder spreading and stable printing conditions.
An ultrasonic sieve with a mesh size of 245 µm reliably removes contaminants and agglomerates during the sieving process. Combined with a dosing accuracy of ±2% during mixing, it guarantees reproducible powder quality. The mixing ratio can be flexibly adjusted to meet specific requirements. All of this takes place in a closed powder loop, protecting operators from direct powder contact and ensuring safe and clean processes.
The system workflow also includes feeding of new and used powder via a membrane pump, as well as discharging sieved and mixed powder into designated containers. For smooth integration into established processes, the system is compatible with various container types, including the customized AM Solutions Polybox, the EOS Multibox, the EOS P3 powder supply bin and the EOS P1 powder bin.
The F1 system mixes up to 40 kg per hour (reference material PA12 (PA 2200)), making it the ideal complement to EOS polymer printers. Additional materials can be processed with the F1 without any difficulty. Thanks to the mobile AM Solutions Polybox with a capacity of up to 180 liters, powder handling and transport are significantly simplified.
System operation is designed to be intuitive: with a user-friendly interface, process parameters can be individually defined, stored, and retrieved at any time, ensuring consistent mixing quality. In addition, the automated process control enables precise monitoring of powder quantities, further enhancing the efficiency and reproducibility of your production.
Benefit from consistent powder quality, stable processes, and maximum safety – thanks to automated, precise sieving and mixing within a closed powder loop.
As the ideal complement, we recommend combining the F1 with our D1 unpacking station. The used powder collected there can be transferred directly into the powder processing workflow – delivering noticeable cost savings and a more sustainable production process. Containers and accessories are compatible with both the unpacking station and the powder handling system.
Key Features:
- Fully automated powder processing: Efficient powder conditioning, sieving and mixing of used and new powder – no manual intervention required
- Reproducible powder quality: Ultrasonic sieving and dosing accuracy of ±2% ensure stable processes and consistent part quality
- Improved powder behavior: Targeted powder conditioning reduces electrostatic effects, improves flowability, and ensures stable printing conditions
- High performance: Processing of up to 40 kg of powder per hour with PA 12 (PA 2200) for EOS polymer printers
- Maximum workplace safety: A closed powder cycle ensures employee safety and clean, dust-free workflows
- Intuitive operation & process control: User-friendly interface for efficient production management
- Ergonomic handling: Mobile Polyboxes simplify powder transport and handling
Automated powder supply – from one to multiple 3D printers
Once the F1 has prepared the powder, intelligent supply systems take over the subsequent material supply to the connected EOS SLS printers. The Direct Feeding System (DFS) enables direct powder supply to a single printer, while the Powder Management System (PMS) provides centralized supply for up to four printers.
DFS: Direct Powder Supply for a single EOS SLS Printer
The Direct Feeding System (DFS) enables direct and automated powder supply to a single EOS SLS printer in combination with the AM Solutions F1. The F1 provides the prepared powder, which is stored in the connected PolyBox as a material supply. As a valve and distribution unit, the DFS controls the filling of the printer and automatically transports the powder to the printer through a permanently installed piping system. This eliminates the need for manual feeding of the prepared powder.
The DFS uses the existing components of the F1. No additional powder pumps, control systems, or media supplies are required. The system control automatically switches between filling the PolyBox and supplying the printer.
Reliable powder conveying is ensured by a grounded aluminum piping system with optimized pipe bends, enabling material transport over distances of up to 6 meters. The plug-in piping can be flexibly adapted to different production layouts and reduces installation effort. Integrated sensors and specially developed filling ports ensure controlled powder transfer without requiring direct signal exchange between the F1 and the printer.
Key Features:
- Direct powder supply: Permanently installed piping connection between the F1 and EOS SLS printer
- Cost-effective operation: Uses existing F1 components, eliminating the need for an additional pump or control system
- Intelligent media management: Automatic switching between PolyBox filling and powder conveying
- Easy integration: Powder conveying over distances of up to 6 meters with preconfigured connection kits including sensors
- Reliable powder conveying: Grounded 40 mm aluminum piping system with optimized pipe bends for reliable, clog-free powder transport
PMS: Powder supply for multiple EOS SLS Printers
For production environments with multiple printers, the AM Solutions F1 can be combined with the Powder Management System (PMS) to create a decentralized solution for automated powder supply. The PMS reliably supplies up to four EOS SLS printers with prepared powder and enables scalable integration into industrial production environments.
Two pre-filled PolyBoxes, each with a usable capacity of up to 180 liters, provide the powder supply. As soon as one container is empty, the PMS automatically switches to the second PolyBox. This keeps the powder supply running during container changes, allowing production to continue without manual interruption.
An integrated weight monitoring system provides transparency on the available powder supply. The recorded information is centrally transmitted via the control system to the user interface, the PolyBox LED lighting, and the 360° warning light. This gives operators a clear overview of the powder supply at all times and provides timely notification when a container needs to be refilled or replaced. This enables material requirements to be identified early and the powder supply to be planned proactively.
The closed powder loop with integrated air return and filtration reduces powder exposure and manual contact with the material. An integrated powder pump enables conveying distances of up to 15 meters, providing additional flexibility when integrating the PMS into different production layouts.
Key Features:
- Automated material flow: Closed powder loop for efficient processes and increased productivity
- High scalability: Powder supply for up to four EOS SLS printers with easy printer assignment
- Increased cost efficiency: Uninterrupted operation through automatic switching between two pre-filled PolyBoxes
- Maximum operator safety: Closed system with air return and integrated filtration
- High process reliability: Integrated weight monitoring for transparent powder availability
- Flexible system integration: Powder conveying over distances of up to 15 meters with integrated powder pump
- Optimal ergonomics: Convenient powder handling with user-friendly working height
- Fast commissioning: Easy startup via a standard 230 V power connection
- Compact integration: Space-saving design and low noise level of <75 dB(A)
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