The Russell AMPro® Sieve Station Connect sieves 900 kilograms per hour, reducing lead times from 13 to 3 weeks
A global manufacturer of flow control systems provides an after-sales service where they produce replacement components for existing pumps using traditional techniques. Each flow control system comprises of multiple components, including valves, pumps, seals, sensors, and actuators. Over time, the components can suffer from corrosion, wear and tear, and the build-up of debris.
The typical lead time to produce replacement parts in this sector is 13 weeks. To meet client demands for faster production, the manufacturer launched a pilot additive manufacturing project. One Italian plant was chosen to trial 3D metal printing of components with 316l stainless steel, to compare with the existing manufacturing process.
As the manufacturer had no previous experience with AM, it looked for advice from its 3D printer provider, 3D Systems, about how to manage powder handling. While visiting other manufacturers’ AM facilities, the company saw that operators often had to lift heavy buckets of powder, a process that was both time and labour consuming.
3D Systems recommended Russell Finex because of the flexibility provided by its range of AM powder handling solutions and the ease of connection to its 3D Systems 350 Flex triple printer. After discussions with Russell Finex, the manufacturer purchased two Russell AMPro® Sieve Station Connect units to sieve and convey both virgin and recycled powder.
During a product trial, the manufacturer successfully reduced the component lead times from 13 weeks using traditional manufacturing techniques to 3 weeks using AM. Russell Finex customized the Russell AMPro® Sieve Station Connect units to automate powder recovery and reloading. The customization has enabled the manufacturer to automatically convey up to 900 kilograms per hour for both loading and unloading the powder from the printer.
The bespoke design empties the printer post-build and refills it, eliminating the need for a lifter. A vacuum system installed on the Russell Finex machines extracts powder from the printer and also reloads the powder via a cyclone boom arm.
With this automation, no manual lifting or loading is required, and the manufacturer’s operators are protected from exposure to the powder. The manufacturer has seen that the parts produced with AM have a more consistent microstructure. In addition, the balancing for rotating components is easier to perform due to the parts’ higher quality compared to those manufactured by traditional casting.
About Russell Finex
We are the only manufacturer in the world that makes our own screening and filtration equipment alongside ultrasonic mesh deblinding systems. We do this for virtually every industry around the world and, with over 90 years of experience, we’ve helped the process industry with measurable impact.
We partner with customers to help them enhance their production lines. By combining high-quality equipment, deep expertise, and the ability to customize solutions, we deliver results while acting responsibly and ethically toward both our customers and the environment.
Contact us today to learn how you can benefit from our sieving solutions.
What our customers say
“Having seen how other manufacturers run their AM, without the same level of automation, we appreciate the possibilities that the AMPro system gives us. It allows us to minimize powder exposure by recovering the powder and reloading it directly to the machine This has dramatically improved the overall powder handling process, reducing time and labor requirements, ensuring operator safety, and cutting job-to-job turnaround time by having the printer ready for the next build in less than two hours.”
