Solving the challenges of cleaning 3D-printed parts

MecWash Systems has collaborated with additive manufacturer Material Solutions to develop a bespoke component cleaning system and a new chemical process to tackle the unique challenges of 3D printing.

Additive manufacturing (AM) leaves behind powder residues that must be removed. Material Solutions uses highly sensitive metals that can stain when cleaned, making the cleaning process particularly challenging. The key challenge was to clean a variety of intricate parts made from super alloy materials without causing staining.

Dave Pawson, MecWash’s in-house chemist, leveraged his experience to develop a solution. Having created thousands of unique wash solutions, he applied his expertise to address the specific needs of Materials Solutions.

“At MecWash, we embrace new challenges and enjoy finding innovative cleaning solutions,” he says. “We were determined to ensure that the high-precision components produced by Materials Solutions were completely free from residual materials. Incomplete removal of substances such as powder, dye penetrant and coolant can severely impact a component’s performance and integrity. We meticulously analysed the samples to identify how we could achieve a superior wash.”

Paul Jarratt, sales manager at MecWash, has worked alongside Dave Pawson for two decades: “We collaborate closely with our customers to develop tailored processes. Materials Solutions required a specialised parts washing system and an original chemical formula to clean their intricate components effectively. After extensive discussions, the MWX600 was selected as the ideal system to handle their range of component sizes.”

He continues: “The MWX600 is highly sophisticated, featuring ultrasonic cleaning, high-flow washing, extended rinsing and vacuum drying. With a large wash chamber capable of holding up to 250 kg, it’s perfectly suited to the components manufactured by Materials Solutions. The company is currently producing components about the size of a microwave and plans to scale up to washing-machine-sized components. I look forward to seeing their continued growth and supporting their evolving cleaning requirements.”

Materials Solutions was highly impressed with MecWash’s meticulous approach, as a company representative reveals: “Since our founding in 2006, we’ve experienced exceptional growth and high demand for our services. Downtime would be detrimental to our productivity, so efficiency is critical. As a premier metal additive service provider, we work with some of the biggest names in global industry to solve complex engineering challenges. We specialise in functional high-end prototypes and serial production applications. Our methods are faster and more precise than traditional casting techniques.

“Working with high-strength, high-temperature materials to create reliable components is our core business. Nearly two decades of experience in metal additive manufacturing have given our team an in-depth understanding of the materials we use. We excel in designing, creating and optimising components.

“Before partnering with MecWash, our cleaning process required manual intervention, slowing productivity and increasing the risk of component damage. Many of our parts feature intricate geometries, including internal channels and lattice structures, which are difficult to clean using conventional methods.

“The expertise and support from MecWash have been invaluable, significantly improving our efficiency. Their deep understanding of chemical compounds has transformed our cleaning process, enabling us to maintain our high standards and productivity.”