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Post-Processing for Powder Bed Fusion Metal Additive Manufacturing


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Published on Aug 16, 2019 SKU SMP-AM-PPME-0819-1 Category Tags ,
Table of Contents

Chapter One: Introduction
Chapter Two: Challenges in Post-Processing PBF Parts

2.1 Powder Removal
2.2 Powder Recycling
2.3 Part Removal
2.4 Support Removal
2.5 Thermal Post-processing
2.5.1 Heat Treatment
2.5.2 Solution Treatment Aging (STA)/Age Hardening
2.5.3 Hot Isostatic Pressing (HIP)
2.6 Machining
2.7 Surface Finishing
2.7.1 Contact Surface Finishing
2.7.2 Laser Surface Finishing
2.7.3 Electron Beam Polishing
2.7.4 Electropolishing and Electrochemical Machining (ECM)
2.7.5 Chemical Polishing
2.7.6 Chemically Accelerated Vibratory Finishing
2.7.7 Abrasive Flow Machining
Chapter Three: Cost Considerations for Post-Processing PBF Parts
3.1 Relative Cost Drivers by Printer Technology
3.2 Relative Cost Drivers by Process
3.2.1 Part Separation and Support Removal
3.2.2 Heat Treatment, HIP and Precipitation Hardening
3.3.3 Surface Finishing
3.3 Hidden Costs
3.3.1 Underestimation of Surface Finish Time
3.3.2 Inadequate Tools for Interior Finishing
3.3.3 Tolerance Issues
3.3.4 Process Knowledge
3.3.5 Skills Gap
3.3.6 Powder Recycling
3.4 Comprehensive Costs
3.5 A Comparison Across Common Alloys
Chapter Four: Post-Processing OEMs and Service Providers
4.1 Post-Processing Equipment OEMs
4.1.1 Powder Removal / Recycling
4.1.2 Thermal Treatment / HIP
4.1.3 Surface Finishing
4.1.4 Integrated Systems
4.2 Post-Processing Service Providers
4.3 Summary
Chapter Five: Design Considerations to Minimize and Optimize Post-Processing
5.1 Powder Removal
5.2 Support Structures
5.3 Orientation
5.4 Internal Passages
5.5 Thermal Processing
5.6 Surface Finishing
5.7 Machining
5.8 Software
Chapter Six: Case Studies and Research
6.1 Chemically Accelerated Vibratory Finishing
6.2 Electropolishing and Chemical Polishing
6.3 Magneto-Rheological Fluid Finishing of Copper
6.4 Laser Polishing of a Superalloy
6.5 Abrasive Flow Machining
6.6 Heat Treatment of Ti6Al4V
6.7 Heat Treatment of AlSi10Mg
6.8 The Effects of Heat Treatment on the Quasi-Static Behavior and Porosity of SLM Produced Inconel 718
6.9 Cracking During Thermal Treatment of PBF-printed CM247LC Nickel Superalloy
6.10 Surface Finishing of PBF Parts by AFM and Electrochemical Machining in Tandem
Chapter Seven: Future Trends
7.1 End-to-end Solutions and Automation
7.2 Data Optimization and Industrial IoT
7.3 Software Solutions
7.4 Standards and Regulations
About SmarTech Analysis
About the Analyst
Acronyms and Abbreviations Used In this Report

As additive manufacturing of metal parts continues to transform from prototyping to production environments, we’ve seen materials expand, systems improve, and automation advance. But, until recently, we haven’t seen an increased focus on post-processing of metal parts produced using powder bed fusion (PBF) technologies.

In this report, we look at the common post-processing steps associated specifically with Powder Bed Fusion technologies, what they can achieve, and the challenges observed. We will discuss the relative cost considerations to keep in mind as well as costs that often go unaccounted for in the PBF post-processing workflow. We will discuss many of the OEMs and service providers that are active PBF post-processing, as well as some specific case studies and research that has been recently conducted. And, often forgotten, we will discuss some of the critical considerations in the design stage that can greatly influence the post-processing stage in the overall workflow. We finish with a discussion on the future trends, to include end-to-end solutions and automation, data optimization, software solutions, and the current state of standard and regulations as they pertain to post-processing.