FORMRISE reduces SLS post-processing time by 50 percent using AM Solutions S1 automated blasting system

German additive manufacturing service provider FORMRISE has integrated the S1 automated blasting system from AM Solutions into its production workflow to optimize Selective Laser Sintering (SLS) post-processing. By transitioning from a manual, multi-stage sequence involving glass beads and polybeads to an automated 2-in-1 process, the company reports a 50 percent reduction in total post-processing time. Managing Director Peter Spitzwieser confirmed that the implementation has led to an annual cost saving of approximately 35,000 euros, driven largely by a reduction in compressed air consumption and a 60 percent decrease in polybead usage. Additionally, the system has helped reduce CO2 emissions by more than 12 tons per year.

This development addresses a major bottleneck in the SLS value chain: the labor-intensive and inconsistent nature of surface finishing and powder removal. In industrial AM service bureaus, post-processing often dictates the final unit cost and throughput capacity. By utilizing the S1's large cyclone separation and integrated vibrating screen, FORMRISE has solved common stability issues related to media contamination, such as trapped glass particles or uneven coloring on light-colored components. This move toward automation is critical for service providers looking to scale production while maintaining the tight tolerances and surface quality required for end-use industrial applications.

For AM service providers, the shift from manual, multi-media blasting to integrated automated systems is a necessary step to stabilize batch consistency and improve margins. FORMRISE must now focus on leveraging this increased throughput to handle higher volumes of SLS parts without increasing headcount. Buyers of SLS technology should evaluate their post-processing infrastructure with equal rigor to their printer fleet, as the S1 demonstrates that media management is as vital to profitability as the build process itself.