IFC uses AM Solutions S1 Shot Blast Machine to reduce cycle times by 70%

With its S1 shot blast machine from AM Solutions, IFC company achieves results within 70% shorter cycle times.

Individually designed orthopaedic arm braces are 3D printed products made by the IFC Intelligent Feeding Components. To guarantee comfort for the patients, the braces must have an "excellent" surface finish. This is achieved with a recently purchased S1 shot blast machine from AM Solutions – 3D post processing technology. 

The IFC Intelligent Feeding Components, located in the state of Baden-Württemberg, Germany, has a 3D print department equipped with equipment. There, 3D metal and plastic print products are made for a range of different industries. Frequently, IFC utilises scans to create specific component designs for the customers. Among other products, the company produces arm braces, which are individually designed and adapted by in-house orthopaedic engineers.  

To ensure a consistently high surface quality in the long run, the company decided to invest in a reliable and cost-efficient mechanical post processing solution. Dominik Riegg, managing the additive manufacturing department at IFC Intelligent Feeding Components, said: "We tested many different systems, before we finally got to talk to AM Solutions at the Formnext 2022 exhibition. What impressed us immediately was that the equipment, built in-house, is very sturdy and, thus, can handle any industrial environment, no matter how demanding this might be. Moreover, the specialists at AM Solutions quickly understood what we need and with the S1 shot blast system they presented an optimal solution."

Poly beads vs glass beads  

At the AM Solutions Customer Experience Center in Untermerzbach, covering an area of 400 m2, the IFC engineers were able to test the proposed equipment beforehand. At the same time, they could inform themselves about the most suitable blast media. Riegg continues: "We decided to use poly beads for our shot blasting process. This media may be a bit more expensive but offers a considerably longer service life than glass beads." An additional advantage of the poly beads is that they create a surface finish that has a more pleasing colour and a satin feel. "The glass beads penetrated the work piece surface, which can be highly problematic in the medical field. With the poly beads we achieve a smooth and highly homogeneous surface finish. This makes the wearing of the arm brace very comfortable” explains Riegg. 

Time savings of 70%

Prior to purchasing the S1 post processing system, the 3D print products had to be unpacked and shot blasted manually. Today, after the unpacking process they are directly loaded into the shot blast machine for cleaning and surface finishing in one single operation. This 2-in-1 solution requires only one single blast medium. The continuous rotation of the work pieces in the shot blast machine guarantees gentle processing and absolutely repeatable blast results. "With our manual shot blasting operation the finishing qualities were very unstable. Now we achieve consistent, high-quality surface finishes and, at the same time, save up to 70% in labour costs" Riegg said.  

Compared to the manual post processing operations, the S1 system handles a two times larger quantity of arm braces. And while the machine is running, the personnel is free to do other work. Riegg said: "Today we increasingly handle smaller work piece batches. To remain cost-efficient, we must automate our manufacturing operations and must have total process stability. Post processing is an essential link in our manufacturing chain and is a lot more than just making a product “pretty.” In the end, automated post processing is essential for achieving consistent, high qualities and allows us to expand our technological possibilities. Our S1 system amortised itself in 1.5 years, but its positive effects for our production will last for a long time.“