Hirtisation remains one of the lesser-known post-processing solutions in additive manufacturing. Yet, when executed properly, it can significantly enhance the surface quality of 3D printed parts while also enabling the automatic removal of support structures.
Forschungs- und Technologietransfer GmbH (FOTEC), the research subsidiary of the University of Applied Sciences Wiener Neustadt, is shedding light on its latest advancements in this area as part of the international joint project Ad-Proc-Add II.
The research team developed an automated post-processing using Hirtisation, the characterization of additively manufactured surfaces, and the development of database systems for process optimization. The electrochemically assisted post-processing method is designed for support removal, cleaning, and smoothing of PBF-LB/M parts.
How the post-processing solution has been developed
FOTEC built on the results of the preceding project, targeted processing strategies were developed for materials such as Ti6Al4V and 1.4404 (stainless steel). By adapting PBF-LB/M process parameters, machining allowances as low as 180–550 µm could be defined—an important step toward material-efficient, automated post-processing. At the same time, surface roughness values of Sa ≤ 5 µm were achieved, enabling the precise functionalization of AM components.
The team conducted extensive investigations into the surface integrity of additively manufactured components. The research focused on analyzing how various PBF process parameters, build orientations, and intermediate treatments influence the final surface properties.
Special attention was given to the interaction with processes such as shot peening, heat treatment, and CNC profile grinding. The resulting surface matrix provides a solid foundation for the targeted combination and optimization of additive and subtractive process steps.
FOTEC’s research efforts were characterized by a strong application focus. Throughout the project, test specimens and use cases were produced and analyzed using materials such as Ti64, 316L, and AlSi10Mg. Close collaboration with the 15 industrial partners—including companies from the aerospace, tooling, and medical technology sectors—ensured that the developed processes could be directly transferred to real-world manufacturing scenarios.
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