The Fraunhofer Research Institution for Additive Manufacturing Technologies IAPT will showcase a new process for removing support structures from additively manufactured metal components for the first time at Formnext 2026 (Booth 120-C51) from November 17-20, 2026 in Frankfurt, Germany. The method utilizes high-frequency mechanical vibrations in the ultrasonic range for an automated process. In addition to improved workplace safety, cost efficiency, and time savings, the new method ensures process stability, reproducibility, and consistent quality.

Effort, Costs, and Risks of the Manual Process

Removing support structures is one of the most labor-intensive steps in the post-processing of additively manufactured components. Delicate or internal structures further complicate an already difficult process.

Manual removal of support structures ties up personnel and leads to inconsistent quality. Furthermore, the working conditions pose health and safety risks to employees, such as the release of fine metal powder particles.

Automation of Support Structure Removal

A method developed by Fraunhofer IAPT automates the labor-intensive removal of support structures. The process utilizes an efficient coupling between the component and an ultrasonic system. High-frequency mechanical vibrations are transmitted from the ultrasonic system to the component and, in particular, to the support structures.

For this new method, the Fraunhofer IAPT combines component-specific vibration excitations with specially adapted support structure designs. This combination specifically generates resonance effects in the support structures and induces local stress peaks at the attachment points to the component. The support structures detach from the component without residue and without manual intervention within a few minutes.

Patent Application Already Filed for Ultrasound-based Process

The new process stems from the »Sonodent« research project, which received funding in May 2026 from the Fraunhofer High-Performance Center IAMHH^®. The solution utilizes cost-effective technical equipment and significantly accelerates the removal of support structures. The patent application has already been filed.

In addition to its use in dental technology, the process can also be applied across various industries and adapted to all 3D printing processes that use support structures. It achieves increased efficiency, reproducibility, high quality, and improved workplace safety. The new process paves the way for additive manufacturing to be adopted in industrial applications.

Noote: IAMHH® is a registered trade mark of Fraunhofer-Gesellschaft.

PR Contact for Fraunhofer IAPT and High-Performance Center IAMHH®

Carola Dellmann
Head of Marketing & Communications

Fraunhofer IAPT
Am Schleusengraben 14
21029 Hamburg
phone:  +4940484010-500
marketing@iapt.fraunhofer.de