Powder condensate is the term used to describe solidified particles resulting from the evaporation of metal alloys during the powder bed fusion additive manufacturing (AM) process. This condensate, which is a waste stream unique to AM, is either deposited into a collection chamber within the AM printer (considered to be “dry” condensate) or wet-vacuumed out of the build chamber itself (considered, along with melt spatter contemporaneously removed, to be “wet” condensate). Both wet and dry condensate may be hazardous and must be disposed of pursuant to applicable environmental regulations. As metal AM is only now entering maturity with respect to production, powder condensate as a waste stream has previously neither been a major concern for operators nor studied widely. However, high volume manufacturers increasingly need to allocate proper resources for the safe disposal of this material. In order to do so, powder condensate should be classified as a separate waste stream and documented appropriately with cost-effective methods for its disposal. This paper discusses the procedures used in the United States for analyzing and disposing of condensate from the powder bed fusion process, and provides a real world example of how one high-volume manufacturer handles this disposal
According to its author, “knowing where each condensate stream is going is just as important as the proper preparation of each type of waste. As Sintavia has grown, we have recognized that proper disposal of all of our waste streams must be a priority. We have worked with Triumvirate Environmental and other experts within the industry to manage the final disposal of these streams according to regulatory requirements.” The full paper is available to AMGTA member companies, other industry stakeholders, and the general public on the AMGTA website at: https://www.amgta.org/resources/.
“We were pleased to work with the Additive Manufacturer Green Trade Association and Triumvirate Environmental on this paper,” said Brian Neff, Sintavia’s Chief Executive Officer. “By sharing what we’ve learned with other industry stakeholders, we hope these published guidelines can help other powder bed fusion AM manufacturers as they develop their own process to determine the safe and proper handling and disposal of powder condensate.”
About Sintavia
Sintavia designs and 3D prints a new generation of flight and launch products for the Aerospace, Defense, & Space industry. The company's ability to design and serially produce thermally engineered components with complex structural walls of less than 150 microns has unlocked a level of performance impossible to achieve using traditional manufacturing methods. With 30 high-speed printers co-located alongside precision post processing equipment, a full complement of mechanical testing equipment, and a full metallurgical and powder laboratory, Sintavia is able to optimize parameters, serially manufacture, and audit quality parts for aerospace applications. A founding member of the Additive Manufacturer Green Trade Association, Sintavia is committed to the highest quality standards in the industry and holds multiple Nadcap and other aerospace accreditations. For more information, visit https://sintavia.com/.
About AMGTA
The AMGTA was launched in November 2019 to promote the environmental benefits of additive manufacturing (AM) over traditional methods of manufacturing. The AMGTA is a non-commercial, unaffiliated organization open to any additive manufacturer or industry stakeholder that meets certain criteria relating to sustainability of production or process. Founding Members of the AMGTA include ExOne, Sintavia, LLC, Taiyo Nippon Sanso Corporation and QC Laboratories, Inc. Participating Members of the AMGTA include AMEXCI AB, BASF 3D Printing Solutions, Danish AM Hub, DyeMansion, EOS, Fraunhofer Institute for Laser Technology (ILT), GE Additive, HP, Inc., Materialise, National Manufacturing Institute Scotland, Rusal America, Siemens Digital Industries Software, SLM Solutions Inc., Stryker, The Barnes Global Advisors, TRUMPF, and 6K. For more information, please contact Sherry Handel, at +1 954.308.0888, or visit www.amgta.org.
About Triumvirate Environmental
Triumvirate Environmental is a leading provider of enterprise waste management and environmental services to Healthcare, Education, Life Sciences and Industrial markets. It prides itself on its attention to safety, sustainability, and innovative solutions. Service offerings include environmental waste reduction, waste management plan creation and implementation, and green and sustainable solution development. Learn more at www.triumvirate.com or call us at 888-834-9697.
