Additive manufacturing:
Copportunities, challenges and the key role of vacuum technology
Industrial manufacturing is facing a paradigm shift. Additive manufacturing, also known as 3D printing, has evolved from a niche process for prototype production to a mainstay of series production. What was once considered a playground for developers is now revolutionising entire industries, from aerospace and medical technology to the automotive industry.
As a manufacturer of vacuum pumps and compressors, that play a key role in almost all additive manufacturing processes, we are observing this development from a very special perspective. In this article, we shed light on how additive manufacturing works, which technologies have become established, what role vacuum technology plays and what challenges and opportunities this dynamic market holds for our company.
1. What is additive manufacturing?
Additive manufacturing describes a process in which workpieces are built up layer by layer from digital design data. In contrast to subtractive processes, in which material is removed (e.g. milling or turning), or forming processes (e.g. casting or forging), additive manufacturing uses only as much material as is actually needed from the outset.
The two most important processes at a glance:
- Powder bed process (e.g. SLM, SLS):
Metal or plastic powder is applied in layers and selectively fused by a laser or electron beam. - Powder Bed Fusion Laser Beam Machines (PBF-LB):
A laser beam melts a thin layer of metal powder to build up a component layer by layer.
2. Why additive manufacturing is booming: all the advantages of the process
Additive manufacturing offers numerous advantages over other processes. Here is an overview:
- Design freedom
Complex geometries and internal structures that cannot be produced using conventional methods can be easily realised. - Material efficiency
Optimised use of materials, less waste, lower raw material consumption. - Functional integration
Multiple components can be combined into a functional component in a single operation. - Customisation
Tailor-made products, for example in medical technology, can be manufactured economically. - Decentralised production
Digital manufacturing allows production to take place where the component is needed. This eliminates complex logistics and long supply chains.
3. Vacuum technology: The backbone of many 3D printing processes
What many users are not immediately aware of is that without vacuum technology, very little works in additive manufacturing. Vacuum pumps and compressors are fundamental components of many 3D printing systems and the associated peripherals.
Where exactly is vacuum technology used in additive manufacturing?
1. Inert gas atmospheres & protective gases
A controlled atmosphere is essential, especially when processing metal powders, for example in SLM or EBM processes. Oxygen and moisture must be excluded as far as possible, as they can negatively influence the quality of the melt and thus the material properties. Vacuum pumps provide an initial pre-vacuum before a protective gas atmosphere (e.g. argon or nitrogen) is introduced. Without reliable vacuum technology, consistently high component quality is not possible.
2. Powder handling and material conveyance
Powder-based processes require precise handling of sensitive materials. Many systems use vacuum conveyors to transport powder from a container into the machine or back into the recycling system. Very clean, oil-free vacuum pumps are used here to prevent contamination.
3. Degassing and post-processing
After the printing process, components often need to be degassed, cleaned or dried. Here too, vacuum pumps perform crucial work, for example in vacuum dryers or plasma degassing systems.
4. Filtration and dust extraction
The processing of fine powders or resins generates dust and vapours that must be extracted and filtered, not only to protect the machines but also the employees. High-performance compressors and vacuum pumps ensure safe and effective air flow.
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4. Requirements for vacuum pumps in additive manufacturing
Additive manufacturing places very specific demands on vacuum technology, both on the machine side and in material logistics. The most important criteria include:
- Process reliability
Stable vacuum levels must be guaranteed, especially in metalworking processes – often under high vacuum conditions. - Purity
No contamination from oil or other contaminants, especially in medical or aerospace applications. Dry-running vacuum pumps are the first choice here. - Compactness and energy efficiency
Additive manufacturing solutions should be as space-saving and sustainable as possible. - Modularity and controllability
Intelligent vacuum systems that can be flexibly adapted to different production modes are advantageous.
As a manufacturer, we are constantly working to optimise our pumps and compressors to meet these requirements through smart controls, robust designs and application-oriented testing in collaboration with machine builders and plant operators.
5. Industry challenges – and how we are addressing them
Despite all the progress made, additive manufacturing still faces a number of hurdles. From the perspective of suppliers in the vacuum and compressed air technology sector, the following challenges are particularly noteworthy:
1. Diversity of processes
Each additive process has its own requirements in terms of temperature, pressure, purity and timing. For us, this means application-specific solutions instead of standard products. That is why we develop modular systems that can be quickly adapted to new plant concepts.
2. Digitalisation and remote monitoring
More and more manufacturers are demanding predictive maintenance and remote monitoring. Our vacuum pumps and compressors are therefore increasingly equipped with IoT interfaces and intelligent sensor technology – for maximum process control and minimal downtime.
3. Sustainability and energy efficiency
Additive manufacturing is inherently more resource-efficient than many traditional processes, but every watt saved counts here too. Our latest compressors operate in an energy-efficient way.
6. Looking to the future: how additive manufacturing and vacuum technology will continue to develop
We are only at the beginning of an industrial revolution with additive manufacturing. New materials, hybrid manufacturing technologies and automated production lines will continue to drive additive manufacturing forward. This also results in new requirements for our industry:
- High-temperature vacuum pumps for ceramic printing processes
- Compact vacuum solutions for mobile printing systems
- Integrated solutions combining vacuum, compressed air and control technology in a single system
The boundaries between mechanical engineering, materials technology and automation are becoming increasingly blurred. This makes it all the more important to have a reliable partner who not only supplies vacuum technology, but also understands it – in all its technical depth and process relevance.
Conclusion
Additive manufacturing has developed from a technology of the future into a production technology of the present. Its future potential is enormous, provided that process reliability, material quality and efficiency are right.
This is where vacuum technology comes into play as a critical enabler. As a manufacturer of high-quality vacuum pumps and compressors, we at Gebr. Becker see our task not only in supplying products, but also in shaping the future of manufacturing together with plant engineers, OEMs and end users. With Becker AMS , we have founded a subsidiary focused on this promising technology.
Whether in material handling, atmosphere control or component finishing, our solutions are in demand wherever precision, cleanliness and reliability make the difference.
If you would like to learn more about our additive manufacturing systems, we are always happy to advise you: Innovation often begins where vacuum reigns.
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