Key Takeaways
- Additive manufacturing (AM) can be just as wasteful as traditional subtractive manufacturing methods
- Powder bed fusion generates approximately 2.5 million kilograms of unused PA12 waste globally each year
- Stratasys' SAF ReLife program enables 3D printing with 100% waste powder, reducing waste and costs
- The program uses a gentler, more controlled process to accommodate aged powder, with three options: Aesthetic, Strong, and Balanced
Introduction to Powder Bed Fusion
Additive manufacturing (AM) is often perceived as a more sustainable alternative to traditional subtractive manufacturing methods. However, the reality is that AM can be just as wasteful, depending on the processes and materials involved. Powder bed fusion, a common AM technique, generates significant amounts of excess material, with approximately 2.5 million kilograms of unused PA12 waste produced globally each year.
The Problem of Excess Material
The excess material generated by powder bed fusion is a major issue, with much of it still usable but unable to be reintroduced without affecting quality. This is due to the thermal aging of polymers during the printing process, which causes material degradation and increases the powder's viscosity over time. The typical solution is to mix in virgin powder for re-use, but this still results in significant waste.
SAF ReLife: A Solution to Excess Material
Stratasys' SAF ReLife program is designed to address the issue of excess material by enabling 3D printing with 100% waste powder. The program uses a gentler, more controlled process to accommodate aged powder, with three options: Aesthetic, Strong, and Balanced. Each option has trade-offs, with Aesthetic taking the longest to print at 17 hours, and Strong being the most commonly selected option among Stratasys customers.
Comparison of SAF ReLife Options
| Option | Print Time | Surface Quality | Mechanical Properties |
|---|---|---|---|
| Aesthetic | 17 hours | Best | Medium |
| Strong | 13 hours | Medium | Best |
| Balanced | 15 hours | Medium | Medium |
Benefits of SAF ReLife
The SAF ReLife program offers several benefits, including reduced waste and costs, as well as the ability to print with 100% waste powder. This makes it an attractive solution for companies looking to minimize their environmental impact and reduce their production costs.
Bottom Line
In conclusion, the issue of excess material generated by powder bed fusion is a significant problem that affects the sustainability of additive manufacturing. However, with the introduction of Stratasys' SAF ReLife program, companies can now print with 100% waste powder, reducing waste and costs. With its gentler, more controlled process and three options for printing, SAF ReLife is a game-changer for the AM industry, enabling companies to produce high-quality parts while minimizing their environmental impact.