Post-processing trends report reveals current methods and challenges

PostProcess Technologies has just released its annual report on post-processing trends in additive manufacturing. This second edition highlights the main methods available in the industry, and the challenges AM users face regardless of the additive manufacturing technology they use. This year, most respondents agreed that post-processing methods are complex and that the search for a skilled workforce that knows how to deal with these post-processing techniques remains one of the biggest challenges, if not a barrier to entry, in the market today. It should be noted, however, that automated solutions are increasingly becoming available, they are also more efficient than previous solutions. This should reassure manufacturers who are more oriented towards mass production.

If post-processing trends are now the subject of an annual report, it is because they are an integral part of the additive manufacturing process. The AM process begins with modeling and ends post-treatment of the part with steps that include surface finishing, removing support materials, etc. It is an important link in the chain that must be taken into consideration. And yet, 20% of the participants say that they do not quantify the expenses associated with post-processing. This is still a high statistic when you consider its importance in the workflow, regardless of the technology employed. It should also be noted that 70% use at least two different technologies – material extrusion remains in the lead followed by photopolymerization and powder bed processes (SLS and LPBF). The more manufacturing processes are used, the more post-treatment methods are used.

Post-processing methods used

Methods used and challenges encountered

Just like last year, the report finds that the most common method used is the removal of printing supports (87%), followed by surface finishing (70%) and finally the removal of materials – resin first (45%) then powder (41%). The study points out that the increase in the number of methods makes the manufacturing process more complex: there is more equipment, more software, while quality level must remain constant. Users can be confronted with deadline issues, but above all of a lack of skills as there are currently very few trainings around this. Knowing how to handle a part once it has come out of the machine is not straightforward, especially when we are talking about industrial parts. Therefore, this qualification is a major challenge for many of the participants in the study, especially for those who use powder bed and photopolymerization processes.