AM Solutions Closes the Loop on Polymer SLS Powder Handling with PMS and DFS Systems

AM Solutions has introduced two new systems — the Powder Management System (PMS) and the Direct Feeding System (DFS) — aimed at automating one of the more persistent manual steps in polymer additive manufacturing: getting processed SLS powder back into the printer. Both systems are commercially available now and will be presented at Formnext.

Extending an Existing Workflow

The PMS and DFS are designed to extend the workflow of AM Solutions' D1 Unpacking System and F1 Powder Handling System into a fully automated, closed powder loop. The goal is straightforward: automate the manual process of powder transfer to reduce labour and increase safety. According to the company, the systems eliminate manual contact with the powder, reduce operator effort, and improve process reliability, occupational safety, and cost-effectiveness.

Two Approaches to Printer Supply

The two systems target different production scales. The DFS provides direct powder supply to a single EOS SLS printing system, while the PMS supplies up to four EOS SLS printers with material — positioning it for multi-printer production environments.

"The PMS enables our customers to supply up to four EOS polymer systems with powder cost-effectively and with minimal operator intervention. Its intuitive operation and closed-loop system make day-to-day production easier and safer. It's another step forward made possible by our close collaboration with AM Solutions," said Magdalena Schwangler, Senior Product Manager Polymer at EOS.

Early Production Experience

Both systems have already seen real-world use. EOS has deployed the PMS under production conditions and reported positive experiences with automated powder supply. On the DFS side, AM Solutions has used the system for internal production operations for approximately ten months.

"The DFS automates the direct powder supply to the printing system, significantly reducing manual intervention in the material flow. Day-to-day production operations have shown that the combination of F1 and DFS enables reliable and convenient printer supply and substantially reduces the manual effort involved in powder supply," added Ann-Kathrin Mahr, Development Engineer at AM Solutions.

That ten months of internal operation matters. Manual powder handling has long been a labour and safety bottleneck in SLS workflows, and a closed loop that spans unpacking, powder preparation, and printer resupply addresses the full chain rather than a single step. Whether the systems deliver on scalability claims will become clearer as more deployments move beyond early adopters.