REM Surface Engineering has introduced a new chemical process designed to significantly simplify the removal of unsintered powder from additively manufactured metal components. The approach addresses a known weakness of powder-based metal 3D printing: the cleaning of complex internal geometries, especially fine channels, which are often clogged with caked powder after the build process.
The process is based on a selective chemical solution that reacts exclusively with non-sintered powder, while the surrounding sintered metal remains untouched. The self-limiting reaction dissolves or loosens the powder so that even hard-to-reach areas such as internal channels can be cleaned efficiently. In an optional post-processing step, chemical polishing can further improve the surface quality.
According to REM, the method has already been used successfully on typical AM alloys such as AlSi7Mg, AlSi10Mg, Inconel 718 and Ti-6Al-4V. Channel cross-sections up to a diameter of 0.5 millimetres could be reliably freed from residues. Tests on single and multi-channel geometries as well as on complex heat exchangers with gyroidal structures demonstrated the adaptability of the process to different component types.
Agustin Diaz, Advanced Manufacturing and Innovation Manager at REM Surface Engineering, highlighted the importance of this breakthrough: „Our innovative chemical approach not only addresses the persistent challenge of powder entrapment in internal channels, but also enhances the overall performance of metal AM components by improving internal surface quality. This development represents a leap forward in the optimization of AM processes and component functionality.“
The chemical approach represents a potentially more economical and reproducible alternative to mechanical or thermal cleaning processes. It could contribute to the standardization of post-processing processes in the additive manufacturing of complex metal parts.
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