Reconditioned PA12 Powder Finds New Life in 3D Printing

A groundbreaking study reveals that reconditioned PA12 waste powder can be fully reused in voxeljet's High-Speed Sintering (HSS) 3D printer, offering a sustainable solution to a common challenge in additive manufacturing.

The study, a collaborative effort between 3D printer manufacturer voxeljet AG, material producer Dressler Group GmbH, and research institute Fraunhofer IPA, addresses the issue of powder reuse in Selective Laser Sintering (SLS) 3D printing.

With SLS, unprinted PA12 powder is typically discarded after repeated use due to degradation caused by high-temperature exposure. This degradation leads to longer polyamide chains, negatively impacting powder flowability and melt viscosity, making it unsuitable for laser-based technologies. The result is high powder refresh rates, creating significant waste and disposal costs.

However, the study found that voxeljet's VX200 HSS platform, which utilises an ink and printhead-based approach, allows for the effective processing of reconditioned PA12 powder. The HSS technology delivers a more selective and gentle energy input, facilitating the gradual sintering of the polyamide and enabling the reuse of the material.

"The VX200 HSS technology is an open-source system, allowing us to quickly change and adapt process parameters to any powder," commented Jan Kemnitzer, Research Team Lead at Fraunhofer IPA. "We were therefore able to quickly adapt the 3D printer to the material with consistent or improved results in part properties."

Prior to testing the recycled powder on voxeljet's 3D printer, Dressler Group pre-processed the used PA12 powder to homogenise and restore key powder properties like flowability and moisture content.

"The results of this study are particularly exciting for ink and printhead-based technologies like HSS," stated Tobias Grün, Global Product Management at voxeljet. "The potential to process this recycled powder on production platforms like the VX1000HSS will deliver substantial cost savings."

He further highlighted the significant impact on cost-effectiveness, "Typically, 50% of running costs are attributed to powder costs. This development offers a huge opportunity to reduce costs while promoting circular material flow and minimising waste."

This research demonstrates a significant advancement in sustainability within the additive manufacturing sector. By enabling the full reuse of reconditioned PA12 powder, voxeljet's HSS technology paves the way for a more environmentally friendly and cost-effective approach to 3D printing.