Matsuura USA has transformed its metal powder recovery process through automation at its LUMEX Additive Manufacturing Center in Minnesota. The new system cuts powder recycling time from 90 minutes to just four minutes while improving workplace safety and material reuse rates – critical advancements for the company’s hybrid 3D printing technology.
Solving a Critical Hybrid Manufacturing Challenge
Matsuura’s innovative LUMEX machines combine selective laser sintering with high-speed machining to produce finished metal parts in a single operation. While this hybrid approach reduces cycle times by up to 45%, it creates a unique material recovery challenge. The process leaves behind fused powder particles and microscopic metal chips that must be removed before powder reuse – a task previously requiring labor-intensive manual sieving.
Custom-Engineered Recovery Solution
VAC-U-MAX designed a turnkey system featuring:
- Vacuum conveyance of powder directly from printers
- Ultrasonic sieving with 63-micron (230 mesh) screens
- Inert gas purging for reactive materials
- Automated controls with touchscreen interface
- Integrated weighing and waste separation
The system’s precision metering feed and anti-static design maximize throughput while maintaining safety standards outlined in NFPA 69 and 484.
Operational and Economic Benefits
The automated solution delivers measurable improvements:
- 90% time reduction in powder recycling (90 min → 4 min)
- 50% labor reduction (2 operators → 1)
- Higher powder reuse percentages
- Elimination of manual handling hazards
“VAC-U-MAX created exactly what we needed – a fully automated system that integrates seamlessly with our hybrid printers,” said Tom Houle, Director of LUMEX NA at Matsuura USA.
Setting New Standards for Additive Manufacturing
As hybrid manufacturing gains traction, Matsuura’s powder recovery innovation addresses a critical bottleneck in metal 3D printing workflows. The solution not only improves operational efficiency at Matsuura’s demonstration facility but also serves as a model for customers implementing LUMEX systems worldwide.
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