Filtration technology is widely used but additive manufacturing has not yet been applied to filter production. The document proposes developing additive technologies for printing filters from metals and ceramics with controlled porosity. This would allow for more complex filter designs not possible with traditional methods. The plan involves developing specialized 3D printers then working with industrial partners to produce and test large filters.

1. © Fine Systems Technologies

2. Filtration is one of the most widely used unit operations. Filters can be
found at any plant and in most devices.
Filtering costs must be accounted for in most plants. Frequently, filtration
materials and their replacement are one of the most expensive costs in
equipment maintenance.
The development of filtration technology and materials does not stop.
quality of air, water, and fuel depend on filters. Filtration is used in the
food or mining industry. Very many aspects of ecology and
protection depend on the quality of the filtration of industrial waste.
Additive manufacturing is not yet involved in the production of filters
and filtration equipment. We offer a project to develop additive
technology for filter production.
It is about printing filters from metals and ceramics.
© Fine Systems Technologies

3. For many decades now, technology has been available on the market to
make filters from sintered powder. It can be a metal powder or a ceramic
one.
The powder is used to form a blank, which is then sintered into a single
piece. The pores between the sintered particles allow liquids and gases
pass, but solid particles cannot pass through them if they are larger.
Such filters have many advantages:
• Permanent, the filter material can serve many years; it has a long life;
• Wide filtration range - from 0.1 µm.;
• Heat resistance. Depending on the material, such filters can operate
temperatures above 1000°C;
• They can be cleaned by different methods. Flushing, heating,
by compressed air, ultrasound or chemical methods, etc.;
• Resistance to mechanical impacts. They can be used to protect
polymer filters from solid particles.
But this technology has limits:
• It's hard to work with powders of different diameters. Because of this,
the pore size in one filter is constant;
• A limited set of shapes. These are only simple shapes such as
disk, and so on.
© Fine Systems Technologies

4. Other types of filters are made of metal mesh. In this case, the filters are
made of woven metal wire. They have a smaller filtration range, as it is
technologically difficult to work with wire thinner than a few tens of
micrometers.
Such filters have a similarly wide temperature range of operation, good
strength characteristics, long operating time and can be cleaned.
The third type of filter is metal fibers, which are distributed randomly.
Non-woven materials made of metal fibers. They have a filtration range
between the ranges of powder and mesh filters.
Modern filters are complex structures. They can be made up of several
layers organized by different filtering concepts. In many cases, they have
protective structures on the surface, supporting structures, and more.
The production of metal filters is a large area of the industry, and there
are companies involved only in this area.
The situation with ceramic filters is similar. Almost all of them have simple
forms.
© Fine Systems Technologies

5. Additive technologies for work with metal are mainly designed to make
products from powders and wires. In some cases, there is a deposition of
molten metal particles on the surface.
We offer the development of additive technologies for filter making.
It could be technology:
• Powder sintering;
• Powder melting;
• Making a product from a piece of wire;
• Formation of the product by deposition of molten particles;
• Hybrid technology. For example, a combination of sintering and
melting powder, a combination of deposit layers of metals and
ceramics in one process
The technologies of sintering and melting powder can be combined in
one device. Since the processes are similar.
By using different technologies, complex structures can be created. For
example, individual layers are printed by sintering powders, while other
layers are printed on another device by applying molten particles.
© Fine Systems Technologies

6. Why do we need additive technology in the manufacture of filters?
One of the problems, which was long solved in additive technologies,
the decrease of porosity of finished parts. The porosity greatly reduced
the structural properties of the finished parts. Now in most technologies,
it was possible to reduce porosity to the minimum possible values, and
technologies of powder melting to achieve its absence.
At the same time, huge experience in controlling the porosity of
has been accumulated. And in the case of powder melting it became
possible to create pores with different purposes in a controlled way.
This makes additive technologies suitable for making metal filters.
In addition, other features of additive manufacturing make it possible to
produce filters with designs previously unavailable.
© Fine Systems Technologies

7. Why use 3D printing to make pores?
Various technologies of designing filtering materials allow in most cases
to make pores with random distribution. The control of parameters of
processes allows us to obtain the necessary distribution of parameters in
defined intervals.
By using additive technologies it is possible:
• Control of pore size. Only the required pore size is formed;
• Regulate the pore size distribution. There will be only a specified
size and filter location distribution;
• Regulate pore shape;
• Control the number of pores;
• Sets the number of pores in the filter;
• Controls pore bonding; For example, create pores that are connected
in the same direction
© Fine Systems Technologies

8. Has anyone tried to print filters?
There are some examples of using 3D printing to make filters. Basically, it
is the first works on the creation of filters for rough filtration.
One of the advantages of technology of the printing of filters appeared
the possibility to make inseparable designs, allowing them to avoid dead
spots. This is especially important in the work of medicine and
biotechnology.
© Fine Systems Technologies

9. Is it possible to increase the filtration area?
One of the parameters defining the filtering efficiency is the filter surface
area.
The surface area of filters is increased in different ways. This includes
folding of sheets, construction of a developed surface, assembly of large
filter elements from many small ones.
However, the number of ways to increase the filter surface area is limited
by the materials and technologies used. Usually, these are either sheets
filter material or cylinders or other simple figures.
With the help of additive technologies, it is possible to create shapes
a larger area than that available at present.
© Fine Systems Technologies

10. Is it possible to mix several layers?
Modern filters are often designed with multiple layers in one. Depending
on the concept, this can be a transition from rough to fine filtration, or a
transition from fine to supporting structures.
Additive technologies make it possible to adjust the pore size at different
filter locations.
In the case of sintering powders, large pores can be obtained. In the
of melting, the porosity can be controlled by pores between grains and
pores from gas bubbles.
With printing, it is possible to obtain a filter as a single product without
using several layers with different porosity.
© Fine Systems Technologies

11. Can printing be done with a protective layer and support?
Many modern filters use a layer to protect against mechanical damage.
Usually, it is a layer of metal with large holes.
This layer can be printed. With the help of additive technologies, this
can be made of complex shape, with the complex geometry of holes to
increase filtration efficiency.
Also, it can be combined with filtration layers to make a complex shape.
Similarly, supporting structures can be printed. They can be created in
thickness of filter layers, between them, behind them.
3D printing possibilities allow making them volume whereas now it either
flat structures or simple volume forms.
© Fine Systems Technologies

12. Can the channels be printed?
Additive technology makes it possible to form complex cavity shapes
inside the main product.
These can be ducts for cooling or heating, removal of part of the filtered
material, filter cleaning by rinsing, or purging.
Can sensors be added?
Embedded sensors within the filter volume can allow temperature,
pressure, and other parameters to be monitored.
This will improve the automation of filter cleaning, more accurately
forecasting filter changes.
© Fine Systems Technologies

13. And the filters are made of metal fibers?
The very necessity of using metal fibers is determined by the
manufacturing technology of existing filters. In the final product, they are
fused at the contact points.
Additive technologies allow printing such structures at once.
The form of such structures can be almost any.
Layers from such structures can be combined with layers organized on
other principles.
Similar structures can also be repeated filters made of woven wire. Only
this case, they will be printed.
© Fine Systems Technologies

14. And the flexible filters?
Flexible filters, based on classic technologies, have their properties
to the properties of a metal. When you create similar structures when
printing - they will be flexible.
Similarly, it is possible to create flat flexible filtering structures made of
metal.
Such filters can be used separately or protective layers of polymer and
fabric filters.
© Fine Systems Technologies

15. Can it be printed by magnetic materials?
Filters made of magnetic materials are needed to collect metal particles.
This is necessary for cleaning air and gases, water and food.
Printing is possible both with special magnetic alloys suitable for casting
and with new technologies.
Currently, our company is developing a technology of printing materials
based on rare earth elements.
Please consider that this technology differs from other 3D printing
technologies and requires a specialized 3D printer design.
The development of the printer under this task can be carried out and
within the limits of this project.
© Fine Systems Technologies

16. Big filters?
Technologies of sintering or powder melting do not yet allow them to
work with large products.
But with additive technologies based on wire melting or spraying of
molten metal particles, it is possible to create large structures.
This is especially important for rotary vacuum drum filtration. Replacing
the filter media in such systems is a major cost item.
© Fine Systems Technologies

17. Where is it needed?
Filters are used in all sectors of industry.
It's filtration:
• Water;
• Air;
• Fuel;
• Oils;
• Food products;
• Melted polymers;
• Exhaust gases;
• In water desalination plants;
• Wastewater;
• On transport;
• In aviation;
• In marine technology;
• In agriculture;
• Power industry;
• Many where else
This is one of the most demanded technologies.
© Fine Systems Technologies

18. What do we offer?
We offer the development of custom 3D printers for making filters.
Specialized 3D printers are necessary because the management of
porosity at the printing of filters demands another approach, than
of integral details.
In the case of fusion of powders, it is necessary to use different lasers for
different operating modes. Sintering and fusion pass in different modes.
Combining these technologies in one product requires a combination of
modes.
In the case of wire melting or spraying of metal droplets, it is necessary
develop special printing heads for controlled porosity of the finished
product.
© Fine Systems Technologies

19. What's the plan?
Using the example of sintering and melting powders
Stage 1
We develop a 3D printer based on systems already developed and
manufactured by us. Such a system should include two independent
for the realization of technologies of making filters from sintered powder,
molten metal, thread-like structures, protective layers, and support
The development may take place in cooperation with a university to
realize the full potential of this technology.
Finished products at the first stage may have geometric parameters
equivalent to those already existing and used filters for testing, informing
potential customers, engineering companies about the availability of
technology, and the possibility to use other designs and forms.
© Fine Systems Technologies

20. What's the plan?
Using the example of sintering and melting powders
Stage 2
Based on the technologies developed in stage 2, we develop a printer
with a larger print area. It is estimated to be 1.2 meters on one or more
axes. For full compliance with industry standards.
For industries where there is no need for high accuracy, it is possible to
significantly increase the size of the construction area.
Development can take place either with a university or with one of the
engineering companies, a potential consumer, an organization involved
commercial R&D.
© Fine Systems Technologies

21. What's the plan?
Using the example of sintering and melting powders
Stage 3
Stage 3 involves interaction with engineering companies to the
of the new filter technology. This is the inclusion of such filters into
projects of new and reconstructed enterprises. Replacement of existing
filters in places where it is possible.
At the same stage, the development of quick print systems for mass
production may be carried out, if this is necessary for such quantities.
© Fine Systems Technologies

22. What's the plan?
An example of wire melting and spraying of metal droplets.
Developing such a 3D printer requires an industrial partner. Because it is
difficult to perform full-scale testing of large filters in laboratories. In case
of work with pilot plants and industrial laboratories, it is possible to
the already described stages for this technology as well.
© Fine Systems Technologies

23. What does our company do?
We develop 3D printing technologies by metals and other materials. We
make and we sell 3D printers.
The main specialization is additive technologies using metals:
• Selective melting and sintering of powders;
• Powder deposition;
• Welding of wire;
• Technologies based on powders and wires
Also, we are now forming the necessary chains to develop technologies
for working with magnetic materials, ceramics (HTS).
This is the development of processes using additive technologies.
Integration of additive processes into production lines.
It includes development:
• Process conditions. For example, the development of heating and
cooling technologies after melting and sintering, controlled cooling,
process atmosphere;
• Technologies for work with different materials. For example,
optimization of work with different alloys, etc.;
• Optimization of individual processes. For example, improving the
optics to support the melting of powders
And even more
Also, we offer the development of technologies in
additive manufacturing.
These are technologies:
• Magnetic materials. Technologies required for
electric motors, generators, etc.;
• Functional gradient materials. Classic
technologies do not allow to realize the full
potential of such materials;
• Superconductors. The creation of products from
superconducting materials is a challenge for
classical technologies;
• Embedded sensors. The potential of Built-in
Sensor Technology is not fully realized in existing
technologies
And many other things...
© Fine Systems Technologies

24. What materials can we work with now?
Now we work with various metals and alloys.
We can list them:
• Steels;
• Titanium;
• Copper;
• Aluminum;
• Magnesium;
• Chromium;
• Nickel;
• Heat-resistant alloys based on tungsten, rhenium, etc.;
• Magnetic cast alloys
For materials in the list, it means both works with pure metals (where it
makes sense) and with their alloys.
It is possible to develop processes for working with other metals and
alloys.
© Fine Systems Technologies

25. In which areas does open architecture apply?
We offer our services and equipment to various organizations and
companies.
These can be manufacturing companies, machine shops, universities.
Main directions:
• Aerospace;
• Marine technology;
• Energy industry;
• Automotive industry;
• Biomedical;
• Chemical engineering;
• Oil and gas industry;
• Food engineering and agriculture;
• Sport;
• Nuclear power industry;
• Railway engineering;
• Infrastructure;
• Tools making and robotization;
• Expensive materials;
• Design;
• Science;
• Superconductors and other
© Fine Systems Technologies

26. Privacy policy
The development of new products and technologies is costly. Preserving
investment in R&D requires compliance with the policy of non-disclosure
of information about it.
This may be a non-disclosure agreement (NDA) or a reasonable
of information to engage third parties for work without the formalizing
agreements.
About us
Our development team has been developing equipment for over 10
years. It is a group of companies, each of which specializes in its own
areas of development in different areas of technology.
We have created the necessary technological chains to carry out the
processes of equipment development, production, and market launch of
products.
© Fine Systems Technologies

27. Team
Stanislav Kozin
CEO
Maxim Burmistrov
Chief product designer
Dmitry Grachev
CTO
Sergey Popov
Software & firmware developer
Alexander Detkin
Engineering technologist
Ilya Vlaskin
Designer engineer
Alexey Mityuryaev
Engineering technologist

28. Contact us:
Fine Systems Technologies
Vladislav Troshin (CEO)
troshin@fine-systems.tech
AddSol
Dmitriy Grachev (CTO)
info@addsol.tech
www.addsol.tech
© Fine Systems Technologies