voxeljet, Dressler Group GmbH, Fraunhofer IPA and the University of Bayreuth Collaborate in Re-Processing of Discarded PA12 Powder for 3D Printing via High-Speed Sintering (HSS)

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Figure 1 – Recycling and printing used PA12 powder is a huge step for circular economy and cost-effectiveness in the AM industry
Figure 1 – Recycling and printing used PA12 powder is a huge step for circular economy and cost-effectiveness in the AM industry
Figure 2 – Printed parts from reconditioned PA12 waste powder (Dressler Group) on voxeljet VX200 HSS, Source Fraunhofer IPA
Figure 2 – Printed parts from reconditioned PA12 waste powder (Dressler Group) on voxeljet VX200 HSS, Source Fraunhofer IPA

Circular economy marks major milestone: recycling nylon waste powder in 3D printing, addressing up to fifty percent of running costs

FRIEDBERG, Germany, November 13, 2024--(BUSINESS WIRE)--voxeljet AG (OTCMKTS: VJTTY) (the ‘Company’, ‘voxeljet’, or ‘we’), a provider of high-speed, large-format 3D printers and on-demand parts services to industrial and commercial customers, Dressler Group GmbH, and Fraunhofer IPA today announced the successful completion of a material study for waste PA12 powder from laser-based 3D printing systems. In the study, waste powder from Selective Laser Sintering systems was successfully recycled by Dressler Group and 3D printed by Fraunhofer IPA at the University of Bayreuth, using a VX200 HSS platform from voxeljet. The initial results demonstrate that reconditioned PA12 waste powder can be processed effectively using ink- and printhead-based High Speed Sintering (HSS) technology enabling sustainable and cost-efficient production. The preliminary test results indicate that the material properties are equal or may even exceed those of comparable prints with fresh powder.

The Challenge: PA12 Powder Degradation in Selective Laser Sintering (SLS) Systems

In SLS systems, unprinted PA12 powder loses its ability to be reused due to high temperature exposure in the build area, which causes the polyamide chains to lengthen after condensation, negatively affecting powder flowability and melt viscosity. This makes the material difficult to process again via laser-based technologies, as the energy input from lasers is too short to process longer molecule chains accordingly. Therefore, comparably high powder refresh rates are necessary, accumulating waste and associated high disposal costs.

The collaborative study aimed to reclaim this used powder by processing it through voxeljet’s VX200 HSS platform. HSS technology, using an inkjet-based printhead and infrared (IR) heating, offers selective and thermally gentler energy input, allowing the polyamide to sinter gradually, enabling the reuse of this powder. This means a real tribute to circular economy in Additive Manufacturing.

Dressler Group, experts in powder design and manufacturing, processed the used PA12 powder to homogenize and recover key powder properties such as flowability and moisture, making it suitable for reuse in HSS.

"Recycling used PA12 powder can effectively reduce costs and support sustainability efforts in AM," says Dr. Ing. Holger Leonards, Head of R&D at Dressler Group. "Our expertise in regenerating powder properties and handling of large powder volumes enables companies to reclaim this valuable material."