Fabrication
Due to the intricate geometry, depowdering was a primary concern. Utilizing CAD, the development of innovative air nozzles was essential for clearing out the loose powder from the various channels and cavities inside the fluid matter exchanger before sintering. Zero powder can be left inside the channels and filters preventing the proper flow of matter and function of the apparatus in the field. Simple handling of these parts in the green state is critical, as the extremely thin walls crack when too much pressure is exercised on them. Internal and external braces were placed in areas that would not affect the function but would aid and reinforce the part for handling during depowdering in the green state and prevent distortion or cracking during sintering.
After sintering, the fluid matter exchanger is inspected and measured with respect to the tolerances on external dimensions. Some post processing is done by the end-user, like welding of the end cap and connectors to the fluid matter exchanger. Advanced tests are performed on each part by the customer, including testing of flowability within the many internal channels and sections as well as pressurized leak testing. These tests are critical in validating the performance of the fluid matter exchanger and ensuring it can be used in the final product.