Fraunhofer IAPT: Ultrasound Removes Support Structures

Metal 3D Printing Ultrasound Gently Removes Supporting Structures

2026-09-11 Source: Fraunhofer IAPT | Translated by AI 2 min Reading Time

The Fraunhofer Institute for Additive Manufacturing Technologies (IAPT) will demonstrate at Formnext how ultrasound helps in the post-processing of printed metal parts ...

Just like that, the supports are gone! High-speed footage of the automated, ultrasound-based process for removing optimized support structures from additively manufactured metal parts. It will be presented for the first time at Formnext from November 17 to 20.(Image: Fraunhofer IAPT) — Just like that, the supports are gone! High-speed footage of the automated, ultrasound-based process for removing optimized support structures from additively manufactured metal parts. It will be presented for the first time at Formnext from November 17 to 20.
(Image: Fraunhofer IAPT)

Formnext in Frankfurt am Main (Germany) will serve as the venue for the first-ever presentation of a new method for removing support structures from additively manufactured metal components. To achieve this, IAPT researchers from Hamburg are using high-frequency mechanical vibrations in the ultrasonic range to develop an automated debinding process. In addition to improved workplace safety, time savings, and cost savings, the new process enables greater process stability, reproducibility, and, consequently, consistent quality of 3D-printed metal parts.

Automated Removal of Support Structures

Otherwise, removing support structures is one of the most time-consuming steps in the post-processing of additively manufactured components. And when these structures are delicate or located inside a component, the process becomes even more complicated than it already is, the report continues. Manual removal of support structures also ties up personnel and results in inconsistent quality. Furthermore, the working conditions pose health and safety risks for employees—for example, due to the release of fine metal powder particles. However, the process developed by Fraunhofer IAPT now automates the labor-intensive removal of support structures.

It "Cracks" Right at the Attachment Point

The basic idea is to couple the component and the ultrasonic system appropriately. According to the explanation, high-frequency mechanical vibrations are then transmitted from the ultrasonic system to the component and, in particular, to the support structures. For this new method, the Fraunhofer IAPT team combines component-specific vibration excitations with specially adapted support structure designs. This combination deliberately generates resonance effects in the support structures and induces local stress peaks at the attachment points to the component. This leads to controlled fracture behavior in the resonance range, according to the researchers. The support structures detach from the component effortlessly and without leaving any residue within a few minutes. A patent application for the process has already been filed.

Does This Always Work with Metal 3D Printing?

The new process is the result of the “Sonodent” research project, which received funding from the Fraunhofer IAMHH Performance Center in May 2026. It also utilizes relatively inexpensive technical equipment and significantly accelerates the removal of support structures. In addition to its use in dental technology, the process can also be applied across industries and adapted to all 3D printing processes that use support structures and metal. The new process paves the way for additive manufacturing to enter industrial applications even a little faster.

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