How does the D3 unpack a build job?
The D3 is a fully enclosed system with three stations. At the loading station, the exchangeable frame from the printer is loaded once the build job has cooled to about 60 °C, and up to 100 °C is possible under certain conditions. An electric actuator pushes parts and powder into a chamber, which moves to the process station and is shaken on a vibration platform. At the discharge station the powder passes through screens into Polyboxes, and the frame base then lowers the parts back without a drop. For a PA 12 build job the cycle takes about 20 minutes, depending on build height and packing density.
Why avoid compressed air?
Compressed air makes parts move and collide, which can damage them. In the D3 the powder stays in the chamber during the first vibration cycle and cushions the parts, which helps delicate geometries. During sieving only the screen vibrates. Dropping compressed air also removes its energy and operating costs.
What does Unpacking Plus add?
For robust parts, the optional Unpacking Plus function runs a second vibration and discharge pass, with powder recovery of up to 95 percent depending on packing density and geometry. A shortened first cycle can also release only the less stressed powder from the edge zones into a separate Polybox. A second pass then sends the powder from the part surface to another box, switched by valve control. Operators can return the edge powder to the powder loop and treat the more stressed powder separately.
Who is testing it and when can it be seen?
The D3 is in beta testing at FKM Additive Manufacturing, which expects less manual work and less operator exposure to polymer powder on large EOS P 7 series jobs. Operation is through a Siemens panel with storable recipes, adjustable vibration duration and intensity, and any build height. The vibration platform can be removed for cleaning. AM Solutions shows the D3 live at Formnext in Hall 12, Stand E79.