3D Printing with Plastics  Closed-loop process chain for additive series production

AM Solutions is expanding its portfolio for post-processing in polymer 3D printing to create a closed-loop system. Two new systems automate the return of processed SLS powder to the printing process, thereby closing the gap that previously existed between powder processing and printer loading. 

With the D1 unpacking station and the F1 powder handling system, AM  Solutions already offers solutions for the automated unpacking, screening, mixing, and conditioning (moistening) of polymer powder. Until now, however, one process step remained largely manual: The powder processed in the F1 had to be fed into the printing systems by hand via an adapter. 

Especially in production environments with multiple systems, this step entailed additional effort and resulted in avoidable employee exposure to the powder. Consequently, there was a significant need for end-to-end automation of powder logistics.

AM Solutions automates powder feeding

With its newly developed powder management systems, PMS and DFS, AM Solutions is now closing this gap in the process. The systems expand the existing workflow from D1 and F1 into a seamless, automated powder cycle and, according to the manufacturer, lay the groundwork for more efficient and scalable series production in plastic 3D printing. 

After printing, the parts are automatically unpacked in D1. The recovered powder is then mixed with fresh powder in F1, sieved, and conditioned. From there, it is either fed directly back to a printer via the Direct Feeding System (DFS) or automatically distributed to multiple printers via the Powder Management System (PMS).

This creates a continuous material cycle, from the printing process through unpacking and powder preparation to the replenishment of the printers. Manual contact with the powder is completely eliminated, operational effort is reduced, and process reliability, occupational safety, and cost-effectiveness are sustainably improved. Particularly in production environments with multiple printing systems, automated powder supply creates the conditions for more efficient and scalable mass production.

AdditivX | January 26, 2027

Additive Manufacturing as a Tool for Supply Chain, Production, and Service

The conference aims to demonstrate how 3D printing with plastics and metals can be used as a strategic tool for spare parts—regardless of the industry. The focus will be on materials, processes, cost-effectiveness, and integration into existing production and maintenance structures, including those from other areas of additive manufacturing.

Key topics of the event:

• Additive Transformation @ Daimler Truck & Buses (Keynote)

• What material and process requirements must a high-performance material meet in additive manufacturing?

• Digital Spare Parts Inventory: Fiction or Reality?

• Regulatory Matters

• Highlight: Guided tour of the SKZ Technikum

Book a ticket now

Direct Automated Powder Feeding 

The DFS was developed to directly supply a single Eos SLS printer (SLS = selective laser sintering). Together with the AM Solutions F1, it automates the powder feed. The F1 supplies the prepared powder, while the DFS, acting as a valve and distribution unit, handles the controlled filling of the printer from the connected Polybox, where the powder is stored. The direct connection is made via a permanently installed pipeline, so that the powder is returned to the manufacturing process without any additional manual steps.

The DFS utilizes the existing components of the F1. No additional control systems, powder pumps, or media supplies are required. The system control automatically switches between filling the Polybox and directly supplying the printing system, thereby further increasing the level of automation.

A high-quality, grounded aluminum piping system with optimized pipe bends ensures a high level of process reliability, enabling reliable material transport even over distances of up to 15 meters. The plug-in piping can be flexibly adapted to different plant layouts and significantly reduces installation effort. Integrated sensors and specially developed filling nozzles ensure controlled powder transfer without requiring a direct signal exchange between the PMS and the pressurization system.

Toner supply for up to four printers

The Powder Management System (PMS) was developed specifically for production environments with multiple printers and enables the automated supply of processed powder. PMS reliably supplies material to up to four Eos SLS printers, thereby supporting efficient scaling of additive manufacturing.

Two poly boxes, each with a usable volume of 180 liters, are connected to the PMS. As soon as one poly box is empty, a valve automatically switches to the second container. The automatic switching between two pre-filled polyboxes ensures a continuous supply of powder and enables uninterrupted operation, thereby increasing productivity. An integrated level indicator uses LED lighting inside the container and a 360° rotating light to signal when a polybox needs to be replaced or refilled. This gives the system operator a constant overview of the available powder supply. According to AM Solutions, the risk of a printer running out of material is virtually eliminated.

Automated, uninterrupted powder supply: AM Solutions' Powder Management System (PMS) integrates two Polyboxes and automatically switches from one to the other as needed.

The fully enclosed system also reduces dust exposure through integrated air recirculation and filtration technology, thereby contributing to significantly improved workplace safety. Manual contact with the powder is virtually eliminated. At the same time, the mobile Polyboxes can be easily transported between F1 and PMS and conveniently connected to the Powder Management System.

Automated Powder Feeding Proves Its Worth in Practice

EOS has already put the PMS to use under production conditions and has had positive initial experiences with automated powder supply. “The PMS enables our customers to cost-effectively supply up to four Eos polymer systems with powder with minimal operational effort. The intuitive operation and closed-loop system make day-to-day production easier and safer,” says Magdalena Schwangler, Senior Product Manager for Polymers at Eos.

The DFS has also already proven its practical viability: At AM Solutions, the system has been successfully in use for about ten months in combination with an Eos P3 Next and the F1 in the company’s internal manufacturing operations. “The DFS automates the direct powder supply to the printing system, thereby significantly reducing manual intervention in the material flow. In daily production operations, it has become clear that the combination of the F1 and the DFS enables a reliable and convenient supply to the printer and significantly reduces the manual effort required for powder feeding,” says Ann-Kathrin Mahr, a development engineer at AM Solutions.

World Premiere at Formnext

With PMS and DFS, AM Solutions is expanding its powder handling portfolio to create a fully integrated process chain—from automated unpacking and powder preparation to the automated recirculation of the material back into the printing process. The two systems close a key automation gap in polymer 3D printing and help users make their additive manufacturing more cost-effective, reproducible, and scalable.

Both systems are now commercially available. At this year's Formnext, AM Solutions is presenting the new systems to an international audience of industry professionals for the first time. (me)