3D Metal Printing Automated Post-Processing Method for Cold Metal Fusion Components

Related Vendors

Headmade Materials GmbH

Rösler Oberflächentechnik GmbH

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

In the Auto-Smooth research project, the participants AM Solutions, Neue Materialien Bayreuth, and Headmade Materials aim to create a seamless process chain for an automated post-processing method for (CMF) components, perfectly tailored to the Cold Metal Fusion (CMF) process.

The initial Auto-Smooth results have already caused a stir in the 3D printing industry: thanks to a technology developed in the first project phase for depowdering and surface treatment in the green state, the post-processing of CMF components was significantly shortened compared to conventional methods. New studies now confirm the potential of the technology and enhance it with the crucial factor of feedstock reuse. A key focus of current research is the automated processing and reusability of feedstock, which is the metal powder mixed with a polymer binder that forms the material base in the CMF process. Previous analyses had already demonstrated that this material is fundamentally recyclable. However, the latest results go far beyond that.

Recycling Rate 100 Percent: Feedstock Reuse As An Economic And Ecological Breakthrough

"At present, everything points to a complete, 100% possible reuse of the feedstock," explains Sven Amon, project engineer at Rösler, who leads the Auto-Smooth project and has been researching and working on the automation and industrial applications of additive manufacturing for almost a decade. "This is a milestone because, until now, manual depowdering or fine depowdering only allowed partial reuse of the feedstock, depending on the component geometry."

Currently, Neue Materialien Bayreuth is conducting detailed investigations into how the reuse of material processed through the Auto-Smooth method affects its long-term performance. A comprehensive lifecycle analysis of the processing material is expected by the middle of next year. Simultaneously, test series are underway to determine the mechanical properties of components made from recycled feedstock, with a particular focus on static load capacity, fatigue strength, and flexural fatigue strength. These studies are being closely supported by Headmade Materials, the inventor of Cold Metal Fusion technology.

The complete recyclability of the feedstock opens up enormous savings potential: what was previously considered waste is now turned into a valuable resource. The closed material cycle drastically reduces material costs, as the excess metal powder feedstock, which is not printed, remains practically indefinitely usable. Combined with significantly reduced disposal costs, this creates an economic leverage effect that makes 3D metal printing with CMF even more attractive for series production.

Fully Recycle And Reuse Process Materials

The ecological impact is also enormous: the 100% reuse significantly reduces the carbon footprint of the entire process chain and ensures a sustainable, resource-efficient manufacturing system. Even the process medium, specially tailored to the technology, can be completely recycled and reused after cleaning and sieving. This represents another lever for cost reduction and environmental relief.

With this dual effect of cost efficiency and sustainability, Auto-Smooth sets new standards in industrial 3D metal printing. The ability to circulate valuable raw materials with almost no loss could prove to be one of the greatest breakthroughs for the profitability of additive metal manufacturing.

Patented Workpiece Holder for the Most Delicate Components

In addition to post-processing, the handling of particularly complex green parts is also a focus of research. Complex green parts cannot be fixed using conventional clamping methods. These parts are so delicate that they would be damaged in a conventional blasting process with a rotating basket. Sven Amon's team has developed a clever solution for this: the delicate components are embedded in a specially printed mesh, which is clamped into the post-processing system. This patented handling system is fully automatable and enables serial processing even for highly complex structures—another step towards complete automation.

"The interest in CMF technology is steadily growing—contrary to the general trend in the additive industry," reports project manager Sven Amon. "This is because CMF makes metal printing economical, especially in prototyping and serial production. With the new post-processing method Auto-Smooth, the process can now reach its full potential."

The Production of Highly Demanding Components Becomes Industrially Scalable

The project, which runs until summer 2026, forms the basis for a new fully automated post-processing system from AM Solutions. Initial test processing in a pilot plant is already delivering promising results. In the coming months, the findings from the feedstock analysis will be incorporated into the pilot system. "With the system that we plan to develop based on the research results, we are expanding our proven 2-in-1 approach—depowdering and smoothing—to include the aspect of sustainability. The result is a 3-in-1 process precisely tailored to the needs of metal printing customers," says Amon. "This will make the production of highly demanding components—such as impellers—economical and industrially scalable. A decisive step through which CMF will finally establish itself as the leading 3D metal printing process."

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