Powder Recovery in Additive Manufacturing

Downdraft gas management system for binder jetting additive manufacturing to prevent powder ejection and combustion during printing. The system uses chutes to collect excess powder from the print bed as it's spread, preventing it from falling off. Pneumatic conveyance tubes connect the chutes to a separate powder collection unit. A gas management system provides a flow of process gas through the system to carry the powder away. This prevents powder from accumulating and combusting in the printer enclosure. The collected powder is separated and stored separately from the gas.

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Efficiently separating excess material from additively manufactured components with complex internal geometries by simulating emptying paths based on fill level and component structure. The method involves moving the component using controlled device motions, measuring the fill level, and simulating emptying paths for different initial fill levels. The simulations use cavity structure to determine pouring directions that shorten path lengths to openings. This allows optimized emptying sequences tailored to the component's internal geometry.

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Automated system for post-processing 3D printed objects to remove excess material and improve mechanical properties. The system uses a spinning rotor to clean the objects by centrifugal force. It can also adjust temperature, apply energy, and collect excess material. Sensors monitor cleaning progress and parameters are adjusted based on feedback. The spinning centrifugal force, temperature control, energy application, and sensor feedback enhance removal of excess material from 3D printed objects.

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Device and method for recovering and re-injecting excess powder in a powder transfer system to improve precision and efficiency when transferring small amounts of low-density powders. The system uses a micro-rotary valve in the loading chamber or storage hopper to recover excess powder weighed above the target amount. This powder is transferred to a recovery chamber. A controller manages valves to form vacuums or supply air to transfer, recover, and re-inject the powder. This allows extracting and reusing excess powder rather than wasting it in normal operation.

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Automated system for cleaning the surfaces of additively manufactured parts to remove residual powder. The system uses sensors to detect powder on the part, then propels cleaning media like air or liquid against the part to remove the powder. It can have multiple cleaning devices and robotic arms to move the part and media around. A suction system extracts the powder and media. The sensors detect powder based on surface characteristics. This allows targeted cleaning of areas with residual powder without blasting the whole part.

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<title>Abstract</title> The reuse of powder in laser bed fusion offers a promising approach to optimizing material usage, reducing costs, and improving sustainability. However, its application the aeronautical sector presents significant challenges due strict certification requirements, process reliability concerns, need maintain mechanical integrity over multiple cycles. This study conducts comprehensive global analysis reuse, considering mechanical, economic, environmental impacts. methodology includes characterization, testing, cost modelling, life-cycle assessment, providing holistic understanding degradation implications. Results confirm that successive cycles lead minor changes morphology an increase oxygen content, yet properties remain within acceptable limits, with slight improvement tensile strength. Economically, significantly reduces 33% decrease observed after single cycle further reductions subsequent Environmentally, assessment highlights substantial benefits, including dramatic reduction waste, energy consumption, carbon footprint, reinforcing sustainability advantage... Read More

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Automated powder removal from additive manufacturing build chambers using sensors to optimize the process. The assembly has a powder removal device inside the build chamber, a sensor outside the chamber to measure particle flow, and a control system that activates/deactivates the removal device based on particle rate changes detected by the sensor. This automates powder removal and allows optimization by sensing when particles stop flowing, indicating completion. It reduces manual monitoring and time compared to stopping based on operator observation.

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Recirculation system for 3D printing powder beds to reduce waste and improve print quality. The system has a powder delivery path from the tank, a repository to store excess powder, and a recirculation path returning powder from the repository to the delivery path. This allows reusing excess powder from the build area instead of discarding it. The recirculation path can have an agitator to mix powder. The delivery and recirculation paths can have heaters. The recirculation system can also include a powder return slot on the build platform to capture excess powder and return it.

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Method and apparatus for efficiently separating additively manufactured components from powder cakes for reuse. The method involves transferring the powder cake into an enclosure and vibrating it solely in the vertical direction using a vibration generator. This breaks up the cake, de-agglomerates fragments, pulverizes adhering powder, and fluidizes the powder. By controlling vibration frequency and amplitude adapted to the cake properties, the process phases are carried out effectively. The apparatus has a transfer station, de-powdering station with vertical oscillator, and processing station to mix and reuse powder.

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Device for recycling selective laser melting (SLM) gradient powders to enable recycling of gradient metal powders used in SLM additive manufacturing without mixing and adhesion of different powders. The device has features like an ultrasonic powder suction device, vertical support frame, screening device, waste material recovery device, powder conveying pipe, cooling device, and controller. It operates in vacuum to reduce contact with air, uses a metal powder sensor to automatically identify powders, and a cooling device to prevent explosions. This allows separating, screening, and recycling of gradient powders without manual intervention.

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Dual direction flow restrictor that prevents debris from clogging the orifice while allowing easy removal of debris introduced during additive manufacturing. The flow restrictor has two flowbody sections, one with slots and a larger diameter section that expands the other section when coupled. This allows debris to be easily removed from the expanded section during manufacturing, preventing clogging of the orifice. In the assembled flow restrictor, the smaller section with slots is received inside the larger section's counterbore.

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A device for cleaning 3D-printed components from adhering powder particles without manual intervention. The device uses a vacuum chamber with a movable component carrier that can be inserted and removed through a pressure-tight door. Inside the chamber, a platform moves in multiple axes to receive the 3D-printed part. Tubular supply lines in the chamber walls generate a volumetric flow when closed. The component carrier and chamber are connected to a negative pressure system. This vacuum pulls the adhering powder particles off the component as it moves inside the chamber. The removed powder is collected in hoppers and sent to a separation system.

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Recyclable resins for 3D printing that can be reground and remade into new 3D printing resins. The recycling process involves grinding or melting printed parts to make a reactive particulate material. This is mixed with additional blocking agents and diluents, then heated to reform a homogeneous solution. Additional photoinitiator, light absorber, etc. are added to make a new printable resin from the recycled material. This allows closed loop recycling of 3D printed objects.

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A process for removing ultrafine particles from atomized powder to improve flowability and other properties of the powder. The process involves contacting the atomized powder with a removal liquid, adding energy to the mixture to detach the ultrafine particles, and separating the removal liquid and detached ultrafine particles from the fine particles. This allows selectively removing the ultrafine particles without significantly impacting the fine particles. The separated ultrafine particles can be recycled back into the process. The resulting powder has improved flowability and other properties compared to the initial atomized powder.

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A method for capturing excess powder from interior passages of additively manufactured parts using removable powder capture caps. The caps are designed with thin membranes that attach to the interior walls of the part during printing. After completion, the caps trap excess powder inside the part. To remove the caps, a tool engages a socket in the cap and twists it until the membrane breaks, allowing access to the powder.

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3D printing of metal objects using inkjet printing and selective powder deposition. The process involves printing a binder solution onto a substrate to create the object's shape layer by layer. Each layer is then coated with a metal powder. The excess powder is removed, leaving the metal selectively deposited in the printed shape. Challenges like oxidation of metal powders during melting are addressed using fluxes or melting in reducing atmospheres.

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Determining the exact amount of powder needed to 3D print a single object in a multi-object print job. This helps optimize powder usage and reduce waste when printing multiple objects together. The method involves calculating the volume of the printed object's outer layer (dilated object) based on the object's shape and the powder layer thickness. It also calculates the volumes of unused powder in the no-build and interstitial areas. Then, it determines the total lost powder based on recycling ratio and the calculated volumes. Finally, it calculates the required powder for the object by adding the used powder from the dilated object and the lost powder contribution.

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A powder removal system for 3D printing that effectively cleans the build platform without disturbing the printed part. The system has a blade to scrape excess powder from between layers without touching the part. Edge and central vacuum nozzles move with the blade to collect scraped powder without disturbing powder on adjacent areas. This allows precise removal of powder between layers without damaging the printed part.

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Creating a powder removal tool during additive manufacturing that can easily access and remove excess powder from inside complex parts with intricate internal passages. The tool is designed as a chain-like structure of interconnected links that can be simultaneously printed alongside the part. After completion, the tool is removed, forcing the powder out of the internal passages. Additional techniques like robotic appendages, vibration, air blasting, or media blasting can further clear remaining powder.

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Reusable metal powder for additive manufacturing that enables stable modeling and defect reduction when recycled. The powder contains an oxide film on the surface, with 0.015-0.106% oxygen content and a maximum oxide film thickness of 200 nm. This oxide layer reduces spattering during melting and prevents defects in recycled powder. The powder is reused in additive manufacturing by repeating melting and solidification steps. The oxygen level and oxide film thickness limits prevent oxide expansion and cracking issues in recycled powder.

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Automated powder removal from additively manufactured parts using a robotic depowdering system. The system has a depowdering station with a robot that grips the part, a nozzle to blow excess powder off, and a blower with an air curtain to contain the powder. This eliminates manual depowdering and allows automated transfer from the printing to sintering furnace.

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Automated system for depowdering and extracting 3D printed parts to simplify and streamline the post-processing steps. The system uses a removable container mounted on a linear actuator to raise and lower the printed layers. An internal apparatus with a sliding perforated plate depowders the layers. A gripper extracts the parts. This allows automated, layer-by-layer depowdering and part removal without manual intervention. The container can be swapped between print jobs.

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A recycling device for FDM 3D printing waste that can crush, melt, and granulate the waste material to regenerate new printing filament. The device has a hopper with a heated screen to chop the waste. The chopped material falls into a melting extruder and is extruded as filament. A granulating device with a rotating cutter cuts the filament into granules that are collected. This allows recycling and reusing FDM printing waste from each stage of the printing process to reduce material waste and costs.

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System for recycling waste materials into 3D printing feedstock with stable quality, enabling recycling of heterogeneous waste materials containing various components. The system generates manufacturing parameters for the recycled materials and device settings to compensate for variability in the waste materials. It analyzes the physical properties of each waste material batch and adjusts the 3D printing process parameters and device settings accordingly. This allows using recycled materials with varying properties in additive manufacturing while mitigating issues like warping and shrinkage.

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Additive manufacturing system with closed material handling to improve efficiency, quality, and safety compared to manual loading and unloading. The system has separate powder and liquid material handling systems that connect to the additive manufacturing machine. Powder is transferred gastight from a drum to the powder system, then to the machine. Liquid materials like binders and cleaners are similarly transferred gastight. This prevents exposure to oxygen and contamination. The machine can also receive blended powder from a sieve that mixes virgin and recovered powder. The closed handling reduces time, improves efficacy, and increases safety for reactive materials.

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Device for automated recovery and reuse of metal powder during selective laser melting (SLM) 3D printing to improve efficiency and reduce waste compared to manual powder recovery. The device has multiple powder collection chambers in series connected to the main powder conveyor. After each chamber fills, powder is automatically transferred to a sieving chamber, then to storage. This allows continuous powder flow during printing without stopping. The sieved powder is returned to the process. The chambers are interconnected pipes and valves.

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Recycling method for spherical titanium powder used in 3D printing that allows reducing the oxygen content in the powder to improve print quality and product properties. The recycling process involves grinding and deoxidation of the 3D printed titanium powder in a hydrogen-rich atmosphere. This breaks the conventional barrier of not being able to reduce titanium oxide with hydrogen. The reduced powder is then 3D printed again to create products with lower oxygen content compared to using the original recycled powder.

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Three-in-one powder recycling mechanism for 3D printers that allows efficient and clean powder recovery during printing without contamination or dust. The mechanism has a printer material tray with divided powder collection ports: two side strip-shaped openings and a horizontal strip-shaped opening. Each bar has a detachable screen. This pre-screens powder before collection to remove larger impurities. The tray has bottom funnels for central and side powder collection. The tray slides on frames with hooks matching pressure holes in the frames. This allows lifting the tray to disconnect the funnels for emptying. The top corner has a sliding tube with an outer ring and spring to lift and disconnect the screen. This enables full screen removal for deep cleaning.

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Powder circulation system for 3D printing to automatically recycle excess powder without manual intervention. The system has a storage device, molding device, spreading device, collection device, and feeding device connected to a mounting piece. Powder is fed to the storage, spread to the molding, collected from excess, and recycled through the feeding. This eliminates manual powder handling steps and prevents exposure while improving efficiency and reducing waste.

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3D printing powder recovery equipment with residual material detection that allows efficient and convenient recycling of unused powder from 3D printers. The equipment has a movable starting plate that pushes the collection tank to collect the powder. It also has a filter plate to separate the powder from contaminants. The starting plate has a handle to move it up and down. When the handle is pulled, the starting plate separates from the vertical groove and moves up. This releases the limit on the horizontal block, allowing it to move the collection tank. The starting plate then pushes the collection tank to move the powder into the filter plate. The filter plate moves down and locks, separating the powder from contaminants. The filtered powder can be easily removed from the collection tank. The starting plate can then be pushed back down to release the collection tank. The filter plate and collection tank are connected to a multi-determination component to move together

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Recycling and reusing metal powder for 3D printing to reduce waste and costs. The method involves crushing and screening the powder from printed parts to separate usable powder from waste. The crushed powder is then screened to separate fine particles. This recycled powder can then be used in 3D printing again. The process avoids needing expensive specialized metal powders and reduces environmental impact from powder waste.

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3D printed metal powder screening system and method to improve recovery efficiency and reusability of metal powder from 3D printing residue. The system uses a multi-stage combined screening device with air flow and vibrating screens configured based on powder attributes. It simultaneously screens powder at multiple sizes to recover usable powder. The screens are monitored by cameras to determine when to turn them over. Analyzing images helps assess when to purge airflow screens to prevent clogging. The screens are reconfigured based on analysis to optimize screening. This improves metal powder recovery and reduces cost compared to traditional screening methods.

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Device for recycling selective laser melting (SLM) gradient powders in 3D printing to increase powder recycling rate, prevent mixing and adhesion of different powders, and enable manufacturing of gradient functional parts with different material compositions. The device separates, screens, and recovers SLM gradient powders in a vacuum environment to reduce air contact and avoid contamination. It uses an ultrasonic powder suction device, vertical support frame, screening device, waste material recovery device, powder conveying pipe, cooling device, and controller. A metal powder sensor identifies powders and a cooling device reduces explosion risk. This automated vacuum recycling helps prevent pollution, waste, and inefficient manual powder recovery.

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3D printing powder recovery and processing device to improve efficiency and reduce waste in 3D printing by automating powder collection, screening, and recycling. The device has a storage barrel, vibrating screen, and mixing barrel connected in sequence above the printer. A suction pipe and isolation device above the storage barrel prevent powder loss during suction. The vibrating screen removes clumps. The mixing barrel with a fan blends the powder. This automated powder handling prevents spillage, knotting, and waste compared to manual transfer.

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A printing powder recovery device for printing presses that can separate agglomerated printing powder from the fine powder during recovery. The device has a dust collection box connected to the fan air inlet. The fan blows the printing powder into a recovery component with two storage boxes. One box has a vibrating screen plate and a scraper slides on the bottom. The other box has a chute with a scraper. An electric push rod moves the scraper to push the agglomerated powder into the second box. This separates the fine powder in the first box from the larger agglomerates.

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A method for recycling and regenerating nylon powder used in selective laser sintering (SLS) 3D printing. The method involves molecular level control to improve the properties of the recycled powder compared to physical additives like friction reducers. The stages are: (1) isolating the residual powder from the printed part, (2) dissolving the powder in a solvent, (3) separating the nylon chains using a specific solvent and temperature treatment, (4) neutralizing the chains to restore their original structure, (5) evaporating the solvent, and (6) spheroidizing the regenerated powder for consistent size and shape. This molecular level regeneration process improves the flowability, melt viscosity, and toughness of the recycled nylon powder compared to physical additives.

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Using recycled thermoplastic powders in 3D printing to reduce waste and lower costs. The process involves recycling thermoplastic materials like PEEK from injection molding, grinding, or other processes, converting them into powder form, and using the recycled powder in a composite-based additive manufacturing (CBAM) process. The CBAM process involves printing the powder onto a substrate, heating and compressing the printed layers, which allows using recycled materials with inconsistent molecular weight and melt flow compared to virgin powder. This opens up applications for recycled thermoplastics in 3D printing, reducing waste, and lowering costs.

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Depowdering additively manufactured parts containing bound metal powder by immersing the parts in a liquid-filled container, agitating the liquid to dislodge unbound powder from the parts, and filtering the liquid to recover the powder. The agitation may be mechanical vibration, gas jets, or heating to create currents that carry away the loose powder. The filtering separates the powder from the liquid for reuse or disposal.

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A build material recovery system for additive manufacturing that uses humidified air to improve the flow and handling of powdered build materials. The system includes a humidifier that adds moisture to the air used to transport the powder between stations in the recovery process pneumatically. The humid air helps to dissipate electrical charges on the powder particles, preventing clumping and sticking that can hinder flow.

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A powder processing unit for binder jetting additive manufacturing that allows efficient curing, sieving, and recycling of build material powder without manual transfer between containers. The unit has dedicated stations for curing new powder, sieving used powder, feeding powder to printers, collecting excess powder, and de-powdering finished parts. This enables automated powder processing optimized for binder jetting compared to legacy methods.

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An in-situ material regeneration system and method for additive manufacturing, such as 3D printing, enables recovery, reconditioning, and reuse of used powders and liquids collected during the AM process. The system and method involve extracting portions of the powder/liquid at various stages, such as after deposition, wetting, and binding, into separate containers. This allows targeted regeneration processes for each type of material. The collected powders/liquids are regenerated separately or mixed and then reused in subsequent print jobs. The in-situ regeneration reduces waste and material costs compared to discarding and replacing used powders/liquids.

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Improved additive manufacturing process for 3D printing using a continuous substrate and segmented carrier frames, along with in-situ material regeneration to reduce waste. The process involves depositing powder on a continuous substrate, removing portions for regeneration at intermediate stations, compacting and drying the powder, and then moving the remaining powder to subsequent stations for binding and printing. The regenerated powders are mixed and reused. This allows selective removal and processing of powder sections instead of entire layers. The regeneration reduces waste compared to external powder recycling.

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Metal 3D printer with automated powder recovery system to prevent loss and improve recycling efficiency. The printer has units to transfer, store, sieve, and process residual powder from the build chamber after printing. A control system monitors powder levels and recovery rates at each step. If recovery falls below thresholds, it adjusts suction, pumping, sieving times, and connections between units to optimize recovery. This allows automated, optimized powder recycling without manual intervention.

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Dust collection and reuse system for powder material processing like filter presses to recycle material that would otherwise be lost during drying and dust removal. The system has a vacuum feeder connected to the drying equipment and dust removal device. When the recovery device collects enough material, it communicates with the feeder to automatically transfer the recovered powder back into the drying equipment for reuse. This avoids waste of fine particles that can be lost during drying and dust removal.

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3D printing waste sorting and recycling device that separates and recovers metal powder, plastic powder, and liquid resin from 3D printing waste. The device has separate mechanisms to first separate the powder from the powder-containing resin blocks, then break up the resin blocks, clean and classify the powder, and finally magnetically separate the metal powder from the plastic powder. This prevents mixing of different types of 3D printing waste during recycling and allows separate reuse of the components.

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A method for preparing solid waste powder for 3D printing, and a 3D printing method using this prepared powder. The solid waste powder preparation involves granulating slurry, drying, and sieving to meet printing requirements. This allows utilizing fly ash, slag, etc. as 3D printing material, recycling waste particles and preventing environmental pollution. The method involves screening, drying, and sieving steps to convert solid waste into printable powder. This allows 100% utilization of waste particles.

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Powder circulation system for metal 3D printers that improves efficiency and reduces waste compared to conventional systems. The system has separate chambers for old and new powder, a vibrating sieve to separate usable powder from waste, and a waste bucket. After printing, the old powder is transferred to the sieve chamber where vibration separates usable powder from waste. The usable powder falls into the new powder bucket for reuse, while the waste goes to the waste bucket. This prevents leaks and ensures complete powder screening.

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Improving the utilization rate of metal powder in additive manufacturing (AM) to reduce costs by reusing powder. The method involves screening, mixing, testing, and packaging used powder to meet reuse criteria. If screening shows poor quality, the powder is remixed with new powder until it's suitable for reuse. This allows recycling and reusing powder multiple times instead of constantly using fresh powder.

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Printing powder recovery system for printing machines that recovers excess powder from the machine body and filters it for reuse. The system has a recovery device with a dust suction pump that pulls powder from the machine through tubes into a collection box. A filter removes impurities. The pump circulates the cleaned powder back to the storage tank for reuse. This prevents excessive powder buildup in the machine and reduces waste compared to just spraying fresh powder each time.

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Efficient and compact powder recovery system for 3D printers that recycles and screens printed powder without taking up extra space. The system has a lifting mechanism to move the print bed up to a screening mechanism at the entrance of the powder storage. The screening mechanism vibrates to sieve the powder as it falls from the bed into the storage. This allows reusing the powder for future prints without needing a separate recovery station.

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