Switching from FDM to SLS for Improved Production
For years, PA12 filament was the go-to material for producing parts for the 22 IDEX 3D printers. However, by transitioning to PA12 powder and using the Formlabs Fuse 1+ 30W SLS printer, the process is now faster, cleaner, and surprisingly more cost-effective. This shift has enhanced part quality and streamlined production.
Step 1: Setting Up the Fuse Sift for Post-Processing
The post-processing workflow starts by activating the fume extraction system and preparing the build chamber. With an extra build chamber, you can start a new print immediately, maximizing production efficiency.
Once the build chamber is unpacked, the process of breaking apart the powder “cake” begins. The sift captures reusable powder, maintaining an impressive 34% packing density, which minimizes material waste.
Step 2: Depowdering with the Fuse Blast
The Fuse Blast automates most of the depowdering process, making it faster and more efficient. The system efficiently collects excess powder, ensuring minimal material loss. The beauty of this method is that 100% of the captured powder can be reused, saving costs on materials.
Step 3: Cleaning and Final Polish
After depowdering, the parts undergo a polishing process in the Fuse Blast. The system offers simplified settings following a recent firmware update, making it easy to select the desired finish. The polished parts emerge clean, durable, and ready for use.
Key Benefits of PA12 Powder and SLS Printing
- Efficiency: With automated depowdering and quick setup, the process saves significant labor time.
- Cost Savings: Producing small functional parts like caps, hinges, and holders is cheaper in SLS than in traditional FDM printing.
- Improved Quality: Parts printed with PA12 powder have smoother surfaces, tighter tolerances, and enhanced durability.
Practical SLS Applications in Production
Switching to PA12 powder has allowed for efficient production of functional parts like:
- Fume extraction hole caps
- Servo mounts and wire shrouds
- Magnet holders for doors
- Power plug holders
- Thin structural components with improved strength
Even small components like custom nylon washers can be efficiently produced, although it’s crucial to evaluate the practicality of printing such items.
Final Thoughts
Adopting SLS printing with PA12 powder has proven to be a game-changer in improving production efficiency, reducing costs, and enhancing part quality. Whether you run a small workshop or a large-scale manufacturing line, this method can significantly improve your 3D printing capabilities.
Stay tuned for upcoming insights on Nylon 12 Tough for even stronger, more resilient parts.
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