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Why We Exist
We exist to drive the mass uptake of metal AM across industry.
As additive manufacturing (AM) is increasingly adopted as a production technology rather than a prototyping technology, it comes under increased scrutiny from a number of different perspectives. When used as a prototyping technology, “good enough” may suffice when it comes to tolerance attainment, surface finish, or precise geometrical conformity with design intent. However, when used for the production of end-use parts, good enough is not good enough, and AM needs to be seen to be not just accurate but also repeatably reliable and cost-effective as a means of production.
Today, there is a huge focus on the post-processing of AM parts and components. Post processing is not only costly, in some instances contributing upwards of 30% of unit cost per part, but in many instances involves manual intervention which introduces part-to-part quality inconsistency, and which is costly, laborious, and in some instances hazardous.
The search for automated post-processing solutions is on-going and vital for the mass uptake of metal AM across industry, and is the reason that Rivelin Robotics exists.
Today, the company focuses on the automation of support removal and targeted finishing to meet the standards of mission critical industries, and will introduce an array of complementary post-processing processes moving forward including, but not limited to, polishing, platform removal, and powder removal.
For support removal and targeted finishing, Rivelin has developed NetShape Robots, an enclosed microfactory that combines an industrial robot — equipped with an array of tools, state-of-the-art sensors and processes to ensure dexterity — driven by the powerful NetShape control software which uses both machine learning and traditional deterministic control theory to optimise the quality and repeatability of support removal and finishing.
The result is an automated support removal solution that reduces defects by 90%, results in a 10-fold reduction in operational costs, and eliminates human risk and variability.
As a company we aim to drive the uptake of AM which we see as a major contributor to a sustainable future, and which will have lasting benefits for our environment. With NetShape Robots we introduce our first breakthrough to achieve this goal.
Today, there is a huge focus on the post-processing of AM parts and components. Post processing is not only costly, in some instances contributing upwards of 30% of unit cost per part, but in many instances involves manual intervention which introduces part-to-part quality inconsistency, and which is costly, laborious, and in some instances hazardous.
The search for automated post-processing solutions is on-going and vital for the mass uptake of metal AM across industry, and is the reason that Rivelin Robotics exists.
Today, the company focuses on the automation of support removal and targeted finishing to meet the standards of mission critical industries, and will introduce an array of complementary post-processing processes moving forward including, but not limited to, polishing, platform removal, and powder removal.
For support removal and targeted finishing, Rivelin has developed NetShape Robots, an enclosed microfactory that combines an industrial robot — equipped with an array of tools, state-of-the-art sensors and processes to ensure dexterity — driven by the powerful NetShape control software which uses both machine learning and traditional deterministic control theory to optimise the quality and repeatability of support removal and finishing.
The result is an automated support removal solution that reduces defects by 90%, results in a 10-fold reduction in operational costs, and eliminates human risk and variability.
As a company we aim to drive the uptake of AM which we see as a major contributor to a sustainable future, and which will have lasting benefits for our environment. With NetShape Robots we introduce our first breakthrough to achieve this goal.
METAL AM: POWDER BED, WIRE ARC, BINDER JET
Support Removal
Support Removal
Problem
Additive manufacturing (AM) requires support structures to prevent sagging and deformation of overhanging geometries. Support removal is the most labour-intensive part of AM post-processing, and when including surface witness removal accounts for upwards of 25% of total part cost. Support removal is a skilled, sometimes hazardous, and always unpleasant manual task requiring years to perfect and leads to variability between parts and from person to person, and introduces inaccuracies that can compromise end-use functionality and design intent.
Solution
The solution is Rivelin’s NetShape Robots with the company’s NetShape control and perception software. This drives a combination of pneumatic and electro-mechanical tools that can remove supports and surface witnesses in a wide range of metallic materials. Rivelin’s Netshape Robots adapt to fixture and part variability using a grinding-specific force control algorithm and a “Scan & Plan” system. Our automated calibration system enables engineers and technicians to quickly set-up and start production runs using their existing levels of knowledge and intuition.
At A Glance
Scan & Plan
Flexible Fixturing
Tool Wear Monitoring
Automatic System
Calibration
Calibration
METAL AM: POWDER BED, WIRE ARC, BINDER JET
Finishing & Polishing
Finishing & Polishing
Problem
Additive manufactured components often exhibit high surface roughness and visible layers. Localised polishing is typically done by hand or in a rigid machine tool, both methods being expensive and introducing quality issues due to the surface variability often found in AM parts. Manual polishing varies over time and from worker to worker leading to unacceptable inconsistencies in production.
Solution
Rivelin's metalworking tools are used to finish, fettle, linish, and polish a wide range of metallic materials. NetShape Robots adapt to surface feature variability using a 3D vision system and dynamic planning capability. Our force control system reacts to machining forces and tracks a desired polishing pressure to achieve a consistent surface finish, and our non-contact tool wear monitoring maintains a stable process.
At A Glance
Scan & Plan
Flexible Fixturing
Tool Wear Monitoring
Automatic System
Calibration
Calibration
METAL AM: POWDER BED, WIRE ARC, BINDER JET
Platform Removal
Platform Removal
Problem
Components often leave additive manufacturing machines attached to a rigid metal platform. Wire EDM is frequently used to de-platform parts, but can be unreliable around metal powder due to shorting and wire breakages. Conventional tools such as bandsaws are susceptible to drift without any form of positional feedback and may cause AM parts to require rework or to be scrapped. EDMs or bandsaws are expensive and large-footprint machines that require skilled operation.
Solution
Rivelin's end-of-arm tools can remove plates and platforms in a wide range of materials, while adapting to warping and variability using a 3D vision system and dynamic planning capability. Our grinding-specific force control system reacts and stabilises non-linear machining forces. Our autonomous programming empowers engineers and technicians with no prior robotics experience to quickly create robot trajectories and tool operations.
At A Glance
Autonomous
Programming
Programming
Scan & Plan
Tool Wear Monitoring
Automatic System
Calibration
Calibration
METAL AM: BINDER JET, POWDER BED
Depowdering
Depowdering
Problem
Unsintered and semi-sintered powder can be found within holes and internal channels of additive manufactured components. If left, residual powder can have serious consequences and can compromise part functionality. The manual work to remove powder is hazardous and often results vary from part to part and from site to site. This variability presents a complex risk in product development that can be costly to manage.
Solution
Rivelin uses a combination of pneumatic and electro-mechanical tools to release caked, semi-sintered, and un-sintered powder. Rivelin's NetShape Robots adapt to variability in the condition and location of holes, corners, and channels using a 3D vision system and dynamic planning capability. Our automated calibration system enables engineers and technicians to quickly set-up and start production runs using their existing levels of knowledge and intuition.
At A Glance
Scan & Plan
Flexible Fixturing
Tool Wear Monitoring
Automatic System
Calibration
Calibration
