Considerations for Metal Fabricators Adding 3D Printing Services

Volkmann Engineer Offers Guidance on Metal Powder Safety, Efficiency

Bristol, PA: Metal fabricators considering investing in 3D printing equipment may be surprised to learn that expanding into additive manufacturing isn’t as simple as expanding the range of services with a new laser cutting machine, according to David Nichols, vice president of sales and marketing for metal powder conveying equipment manufacturer Volkmann USA, Bristol, PA. Nichols offers the following considerations for metal fabricators interested in offering 3D printing services:

Additive Manufacturing Reverses Subtractive Machining

Metal additive manufacturing involves a completely different set of machinery and equipment than traditional subtractive metalworking and comes with distinct safety risks. Instead of removing material with machining and cutting, additive manufacturing starts with fine metal powders and layers them into a solid part. Since many fabricators lack experience in working with bulk powders, they may also lack an understanding of their inherent dangers.

Metal Powders: Toxic and Explosive

Metallic powders such as cobalt, tungsten, aluminum, copper, and others commonly used for 3D printing are toxic in varying degrees and milled to very fine particle sizes that must not be inhaled. These powders are also ignitable and labeled combustible by NFPA. Each step in the 3D printing process invites opportunities for powder spillage and worker exposure that need to be addressed in advance to prevent serious injury, disease and/or a catastrophic explosion.

Role of Automation

Now that the industry has begun to mature, a slate of automated metal powder handling solutions is available to address the safety risks, improve efficiency, and protect powder purity for consistent part quality. A sealed, closed-loop system developed by Volkmann in collaboration with BMW Group and GKN Additive, for example, automatically transfers the metal powders from storage to the printer inside enclosed piping, then extracts any excess powder from the printer, sieves it, and readies it for recycling and reuse. Automated part removal is also available. This system earned the ATEX certification as explosion-proof, eliminates risk of toxic exposure, and allows the 3D printing system to operate without a separate room or facility.

When considering offering metal additive manufacturing, it is useful to involve engineers with expertise in powder handling for 3D printing early in the process. This helps to avoid costly and potentially dangerous errors and ensures the new service may begin generating ROI as quickly as possible.