AM-MPRR™: Metal Powder Recovery & Reconditioning System for Additive Manufacturing

Overview

The AM-MPRR™ (Additive Manufacturing Metal Powder Recovery & Reconditioning System) manages the entire lifecycle of metal powders for powder bed laser fusion and binder jet printing, combining powder extraction, sieving, and reconditioning into a single, automated, closed-loop process.

• Reduce Waste: By effectively recovering and reconditioning unused metal powder, AM-MPRR minimizes waste and maximizes material utilization.
• Reduce Costs: Material usage optimization and streamlined operations lead to significant cost reductions in overall printing workflows.
• Improve Efficiency: The combined vacuum removal and sieving process significantly reduces downtime, resulting in faster printing cycles.
• Protect Your Workforce: Automated handling, closed-loop system, and inert atmosphere significantly reduce exposure to hazardous or reactive dusts and minimizes explosion risks.
• Enhance Sustainability: AM-MPRR promotes a more sustainable AM environment by minimizing waste and optimizing material usage.
• Maintain Quality: The system ensures reconditioned powders meet the high-performance standards required for critical AM applications, preserving valuable material.

The system employs advanced pneumatic conveying to fully extract metal powders from the build box, sieving out foreign debris and oversized agglomerations, then reconditioning the on-spec powder for reuse.

For use with all AM metal powders—both reactive and non-reactive—including titanium, aluminum, and nickel alloys, water-reactive powders, Iconel^®, stainless steel, Haynes 282^®, and cobalt chrome.

Learn more about our metal powder recovery solutions →

Process

RECLAIM

• The AM-MPRR system utilizes an innovative vacuum conveyor developed by VAC-U-MAX specifically for metal powders, including reactive versions that must be handled in an inert atmosphere.
• This technology safely and efficiently removes unused metal powder from the build box, eliminating the need for manual handling and reducing the risk of operator exposure and/or explosion.
• After separating the powder from the airstream, the conveyor then directly deposits the recovered powder onto a sieve to remove oversized materials before conveying the powder once again into the tumble blender for further processing.

RECLASSIFY

• A key component of the AM-MPRR system is a vibratory sieve from VORTI-SIV.
• This sieve incorporates an ultrasonic anti-blinding device ensures continuous operation and removes oversized particles and contaminants from recovered powder.
• VORTI-SIV’s sieving technology plays a crucial role in maintaining consistent reusable powder quality for successful printing through multiple cycles.
• Standard sieve is a single deck with 63-micron screen cloth, but other sieve sizes and side outlets are also available.

RECONDITION

• The recovered and reclassified powder enters GEMCO’s tumble blender, a renowned solution for powder homogenization in the AM industry.
• Residual identical powder from multiple printers can be delivered to the tumble blender to be homogenized into a consistent masterbatch for reuse.
• The optional GEMCO precision dryer can dry material to a single-digit moisture content to improve powder flowability.
• Tumble blenders and dryers are the most efficient devices for metal powder reconditioning.
• Flowability can be increased by using heat and gas purging.

Specs & Features

VAC-U-MAX VACUUM CONVEYOR

• Rated for 1500 lb (680kg) per hour throughput.
• Single venturi power unit: no moving parts, no electricity, no heat, no lubrication
• Operates on compressed air or inert compressed gas without modification
• Easily cleaned without tools, interior welds are continuous and ground smooth, interior surfaces are polished. Stainless steel product contact parts.
• Reusable primary filter, PTFE coated, static-conductive, rated 99.9% @ 1 micron,
• Secondary HEPA filter rated 99.97% @ 0.3 micron
• Provision to capture exhaust air with inert gas (when applicable)

VORTI-SIV SCREENER

• Standard 15” (380mm) round sieve with single electric vibrator motor
• Stainless steel screen cloth is 63 micron with ultrasonic anti-blinding system
• Other sieve sizes, screen materials and side outlets are available
• Rescreenable screen mesh – save money!
• Visual inspection port on sieve cover

GEMCO TUMBLE BLENDER or DRYER

• Standard 2ft3 (57 liter) rated batch capacity
• Tumbling action is most efficient and effective method for blending metal powders.
• Blender version takes identical powders from multiple printers and delivers a new homogenous mix.
• Dryer version removes moisture that ruins powder flowability. Achieve single-digit moisture levels and renew your powder to “flow like water” again.
• TEFC Gearmotor with rotation speed range between 5-25 RPM.

FEATURES

• Full powder recovery
• NFPA 484-compliant
• Recovers both reactive and non-reactive metal powders, including water-reactive powders, Iconel^®, stainless steel, Haynes 282^®, and cobalt chrome.
• Reduces cross-contamination of powders
• Screened powder is available for immediate reuse, blending with virgin materials, storage, or recycling
• Minimizes operator exposure

MOBILITY

• Vacuum conveyor and sieve are mounted on an easy-rolling square-tube frame, and blender / dryer is mounted on a separate heavy-duty frame with forklift pockets and heavy-duty casters.
• Easy set-up and transport in crowded printer rooms.
• Power and control cords are fitted with quick-disconnects

SAFETY

• Static ground circuit monitoring with interlock to prevent system operation if grounding circuit is not complete.
• Blender/Dryer is equipped with safety doors with controls interlock switch.
• Inert gas manifold with purge fittings across the entire AM-MPRR system for reactive metal powders.
• Stations for blender loading hoses with interlock ensure that hoses are disconnected before blender/dryer can rotate.

CONTROLS

• UL-certified NEMA 4 control panels.
• System panel is equipped with an HMI and PLC.

About the Collaboration

230 years of combined expertise lead to flawless collaboration.

The AM-MPRR™ is a collaboration between industry leaders VAC-U-MAX, GEMCO, and VORTI-SIV — collectively representing over 230 years of powder handling, processing, and manufacturing expertise.

Since 1954, VAC-U-MAX has specialized in the design and manufacture of bulk material handling systems and support equipment used for conveying, weighing, and batching of dry bulk solids.

GEMCO has been providing best-in-class tumble mixing and drying solutions since 1916. A fourth-generation family-owned industrial manufacturer, GEMCO has engineered, produced, and installed thousands of mixers and dryers worldwide and operates the largest tumble mixing and drying technology center.

Since 1968, VORTI-SIV has been a leading manufacturer of the highest-quality sieves, screens, and separation equipment. They service many industries, including food, pharmaceuticals, nutraceuticals, ink, paint and coatings, powder metals, and cosmetics. Their lab, pilot, and production-size equipment are used worldwide for many high-quality wet and dry processes.