Additive Manufacturing

For finishing, surface and economic processes

 LUKAS-ERZETT offers tool solutions with which 3D printed products can be reworked faster, more precisely and more efficiently.
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Tool solutions for support structures, surfaces and finishes

When post-processing determines time and costs

3D printing, also known as additive manufacturing, offers many advantages - in the production of prototypes as well as small and medium series and increasingly also in series production. However, only in the rarest of cases do workpieces and components come out of the printing process ready for use. Support structures have to be removed, staircase effects on bevels and radii smoothed, drill holes cleaned, flat surfaces produced and surfaces finely finished or polished. In other words, post-processing, which can be time-consuming and costly, is one of the biggest challenges in additive manufacturing today. LUKAS-ERZETT offers tools with which these tasks can be completed with high quality, precision and efficiency.

Quality often only emerges after the printing process

Additive manufacturing and post-processing belong together

From the idea and design to final acceptance, every workpiece in additive manufacturing goes through many different work steps. Whether prototype, demonstration model or small series - post-processing is of particular importance. This is because perfect, yet rapid post-processing of the often delicate and thin-walled 3D printed workpieces not only contributes to reduced costs, but is also crucial for the quality and quality of the end result. Tools that are precisely matched to these requirements in terms of performance, geometry and area of application are important here.

Work efficiently from cut-off to finish

Solutions for post-processing in additive manufacturing

When removing support structures, smoothing staircase effects on bevels and radii, producing flat surfaces, cleaning holes and final polishing, the requirements for efficient and high-quality post-processing are complex. This is precisely why LUKAS-ERZETT offers tools and customised solutions that have been specially developed for the post-processing of additively manufactured components. This is based on more than 85 years of experience in the manufacture of application-optimised tools for milling, grinding, polishing and cutting, as well as close cooperation with 3D printing companies.

The post-processing process in additive manufacturing

Four steps to the perfect 3D print result

01 - Removing the support structures

In the first step of post-processing, the support structures often required for 3D printing must be carefully removed without causing damage to the component.

02 - Rough processing of the surfaces

In the second step, the surfaces are roughly reworked. This includes the careful reworking of the connection points of the removed support structures, the smoothing of existing step structures and the rough adjustment of the entire surface of the 3D component.

03 - Finishing the surfaces

In the third step, tools characterised by their special tool geometry and finer grain size are used for fine grinding the surfaces. This means that even hard-to-reach areas can be further optimised and fine-ground.

04 - Surface finishing

In the fourth and final step, the surface is given its final polish. Special polishing tools in various shapes, sizes and degrees of fineness are used here, which ensure the desired high surface quality even on the smallest, almost inaccessible areas of the 3D workpiece.

EasyFinish 3D 10-Piece Tool Set, 3mm shank
EasyFinish 3D 10-Piece Tool Set, 3mm shank

EasyFinish 3D Set (10 pieces)

HFAS Cylindrical Burr for Steel, 12x25 mm, 6 mm shank | Face-toothed, 7-tooth | TiALN-coated
HFAS Cylindrical Burr for Steel, 12x25 mm, 6 mm shank | Face-toothed, 7-tooth | TiALN-coated

HFAS 1225.06 Z7 TiAlN Steel, TiAlN-coated

P2ZY Polishing Point, Cylindrical Shape, 20x20 mm, 120-grain | 6 mm shank
P2ZY Polishing Point, Cylindrical Shape, 20x20 mm, 120-grain | 6 mm shank

P2ZY 2020.06 grain 120 red

The EASYFINISH 3D tool set from LUKAS-ERZETT

A solution for many typical 3D post-processing tasks

From cutting off support structures, smoothing staircase effects and cleaning drill holes to fine machining and perfect surface finishing - the EASYFINISH 3D tool set provides a tool system tailored to the requirements of 3D post-processing. The included milling, grinding and polishing pins are durable, powerful and can be used for practically any material used in 3D printing. They enable fast work progress and precise work results.

The standardised 3 mm shank of all tools also contributes to greater efficiency during post-processing. This means that only one drive unit is required for all applications. This simplifies handling and supports economic processes in the workshop, development and production.

Utilising the advantages of both processes in industrial practice

Additive manufacturing, subtractive post-processing

Additive manufacturing offers a high degree of design freedom, material efficiency and the ability to produce components with complex geometries, integrated structures and cavities quickly and efficiently. Subtractive machining takes over where dimensional accuracy, surface quality and functional surfaces are crucial. Particularly in sectors such as the automotive industry, aerospace, medical technology and machine, plant and mould construction, it is clear how well the two processes complement each other. LUKAS-ERZETT offers tools and customised solutions that allow the strengths of additive and subtractive manufacturing to be optimally utilised.
The right solution for your problems Innovative tools as problem solvers

As an expert in the processing of surfaces with many years of experience in the fields of milling, grinding, polishing and cutting, LUKAS is a competent and reliable partner, especially when it comes to pioneering and new technologies such as additive manufacturing. The broad product range offers solutions for many special applications.

Dr Andreas Mettenbörger, additive manufacturing specialist at LUKAS, sees the tool manufacturer's strengths here: "The LUKAS tool range is ideally positioned for the post-processing of 3D printed products of any type and shape - regardless of the material.

Our extensive product range offers exactly the right solution for all post-processing problems."
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FAQ Frequently asked questions and answers on the topic: Additive manufacturing and post-processing

Additive manufacturing refers to various processes in which components are built up or manufactured layer by layer. Depending on the workpiece and the process used, different materials such as various metals or plastics can be used.

The terms 3D printing and additive manufacturing (AM) are generally used to describe the same manufacturing processes.


Other terms also include generative manufacturing and rapid technology.


Rapid technologies include rapid prototyping (RP), rapid tooling (RT), rapid manufacturing (RM), direct manufacturing (DM) and rapid repair (RR).

There are several different manufacturing processes. In addition to so-called sterolithography, a general distinction can be made between so-called free-space processes and powder bed processes.


In free-space processes, the workpiece is built up layer by layer in free space. In the powder bed process, the workpiece is manufactured on a platform with a powder bed that is lowered layer by layer.



Stereolithography


In stereolithography, liquid plastic (photopolymer) is applied layer by layer with a moving laser, solidified (polymerised) and thus a 3D structure is created.


Free-space process:


Fused deposition modelling

In fused deposition modelling, a cord or wire-shaped plastic is heated and melted onto the tool layer by layer.


Laser metal deposition

In laser metal deposition (build-up welding), the component is built up layer by layer using a metal wire that is welded to the underlying layer by a laser beam.


Powder bed process:


Binder jetting

In binder jetting, so-called binder droplets are applied to a material powder layer by layer, bonding the powder together. The powder can consist of a wide variety of materials such as plastic, metal or ceramic. The component is then given its final strength in a further process step.


Selective laser sintering

In selective laser sintering (SLS), the 3D object is created by using a moving laser beam to solidify a polymer powder layer by layer and bond it to the underlying material.


Selective laser melting

Selective laser melting (SLM) also uses a moving laser. The metal or ceramic material powder is melted onto the 3D workpiece layer by layer.

Depending on the process used, different materials are utilised. These include various plastics such as epoxy resins and polyamide, various tool steels and stainless steels as well as metal alloys based on titanium or nickel and ceramic materials such as silicon carbide or aluminium oxide.

Depending on the method and object, additive manufacturing comprises many processes that can be roughly divided into six work steps:

  1. Design of the 3D component
  2. Building process/manufacturing (printing)
  3. Removal from the platform
  4. Post-processing, manual
  5. Post-processing, mechanical
  6. Inspection/quality assurance