Automated powder handling shortens AM lead times in spare parts production

A global manufacturer of flow and control technology is accelerating spare parts production with automated powder recovery and feeding. The core of the new process chain comprises two Russell AMPro Sieve Station Connect units, coupled in an Italian pilot plant with a 3D Systems 350 Flex Triple for 316L components. According to the project, lead time dropped from a former 13 weeks to about three weeks, while occupational safety and powder management were also improved.

The stations handle the screening and conveying of virgin and recycled powder and are integrated into the printer setup so that build-job emptying and refilling run automatically. A vacuum conveying system with a cyclone boom enables a closed material loop that minimizes exposure to metal powder. In trials, Russell Finex configured the system for throughputs of up to 900 kilograms per hour; manual lifting operations and external lifters are eliminated. For operators with no prior AM experience, the solution addresses typical weak points in the powder chain, such as media breaks, contamination, and inconsistent screening quality.

Beyond the logistical effects, the user reports quality gains: parts show a more uniform microstructure, and balancing rotating components is easier because the dimensional accuracy of additively manufactured geometries is higher than that of cast variants. These observations are consistent with common experience in the metal powder bed and laser powder bed fusion environment, where reproducible powder fractions and defined moisture and oxygen limits significantly influence part quality.

From an operational standpoint, automating powder handling is a lever to make additive manufacturing economical beyond one-off parts: shorter setup and handling times, fewer stoppages due to manual transfers, and a traceable powder history. Critical for scaling remain the validation of screening and conveying parameters per alloy, clean segregation of batches, and integration into MES/QM systems. If achieved, AM for spare parts in small to medium volumes becomes a plannable option alongside conventional processes.