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Filters remove undesirable material from an environment using various physical, mechanical, and chemical processes, and are an important component used in many different industrial, commercial, and consumer applications.
Industrial filtration is a big market
The global industrial filtration market is already large and is expanding quickly. In 2021, it was estimated that filter manufacturers were generating over $72 billion (USD) in revenue, and with a compound average growth rate of 5.1%, they are expected to exceed $112 billion by 20302.
Three main categories are leading the filtration market:
- Internal combustion engine (ICE) — Led the market in 2021, with over 42% of all revenues. The demand for these products is being driven by the automotive industry, which is under pressure to improve fuel efficiency and further reduce emissions.
- Fluid — Much of the growth in this segment comes from governmental agencies who are constructing new treatment plants to provide safe water. However, they are also used in many other markets, including beverage and pharmaceutical manufacturing, petroleum refining, and dairy processing.
- Air — This segment is expected to experience the fastest growth by 2030, in large part because of government action to reduce air pollutants. But air filter manufacturers are also experiencing high demand for products that remove pollen, allergens, and other particles from homes, offices, and public transportation.
How are companies manufacturing filters today?
Sintered metal filters are most often used in the air and fluid market segments. There are a wide variety of types available ranging from basic mesh disks and tubes to complex cartridge filters with multiple layers. In most cases, these filters are made from sheets of wire or perforated metal, which are welded together, and sintered, which subjects them to high temperature and pressure.
Because of specific needs for each application, sintered metal filters are often manufactured to order. When manufacturing filters, the process and materials must allow for many attributes, including porosity, permeability, pressure drops, temperature, and strength. Sintered metal filters are also designed to withstand high temperatures, pressure, and corrosion. Often, they must also be non-reactive to liquids or gasses, all the while maintaining a consistent flow rate.
Why is there so much interest in 3D printing filters?
In the past, additive manufacturing (aka 3D printing) was primarily used for mockups and prototyping. But in recent years, the technology has become more capable and less costly, making it a better option for bridge and end-use parts production. Some of the biggest beneficiaries are companies who are 3D printing metal parts.
Metal 3D printing enables engineers to utilize design for additive manufacturing (DfAM) to develop new parts that are lighter in weight and offer better performance. It also allows parts to be consolidated for easier assembly, and the digital workflow provides improved efficiencies and economics, while reducing the friction and cost associated with customization.
What do filter manufacturers need to know about 3D printing metal parts?
There are many different metal 3D printing solutions available today. Some are limited in terms of capabilities, and cost, but binder jetting is ideally suited for filter manufacturing because it offers exceptional quality and performance, a wide range of materials, and compelling economics.
HP’s Metal Jet 3D Printing Solution uses binder jetting to produce metal parts. The layer-by-layer process employed by this technology eliminates the need for supports, which simplifies post-processing and finishing. It also utilizes standard metal powders from established suppliers, which increases cost efficiency. HP’s Thermal Inkjet printheads help expand the economic advantage, while also delivering excellent quality. In addition, HP’s technology minimizes the amount of binder agent, which allows thicker parts with larger mass.
Schneider Electric innovates by 3D printing air filters
Schneider Electric is a global leader in energy and automation. The company provides hardware, software, and services, and its customers include everyone from consumers to large-scale, industrial enterprises.
Among its many offerings, Schneider Electric provides 690V switchboards for large oil & gas factories. The switchboards contain four small, but vital filters that are a crucial part of the safety system. In the past, Schneider Electric designed and produced them using traditional manufacturing technologies. Working with HP and GKN, a leading producer of materials and products using metal powder technologies, Schneider Electric began 3D printing metal parts.
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They collaborated with GKN to design the new filters and scale production. By 3D printing filters, Schneider Electric benefited from a robust process, high productivity, and great surface, while lowering their costs considerably. Further, manufacturing filters with 3D printing increased the sustainability of their switchboards, reducing their carbon footprint by 20%.
“The benefits I see with HP Metal Jet technology are process robustness, high machine productivity, and surface finish," said Guillaume Fribourg, Metallic materials & processes expert in Energy Management BU, Schneider Electric. “Now we do consider HP’s Metal Jet technology a viable option for serial part manufacturing. We plan to leverage this technology across Schneider Electric’s lines of business to bring new added value to our products and customers.”
Watch how Schneider Electric is transforming filter production with metal 3D printing from HP and download the full 3D printing filters case study.
Other opportunities for filter manufacturers
Porous disks are a common type of metal filter. They are used in many applications for several reasons. First, they are relatively easy to vary by shape, diameter, thickness, and grade. In addition, they can be encapsulated in various metal and non-metal parts. Furthermore, they can be easily cleaned and are typically reusable for considerable periods of time.
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There are several benefits to 3D printing filters such as porous disks using HP Metal Jet technology. HP Metal Jet technology enables large-scale production of disks with complex geometries, which allows engineers to vary and control porosity on the disk through innovative design with HP Metal Jet processes. Additionally, the near-net shape of porous geometries provides companies with faster speed-to-market and helps simplify their supply chains.
Interested in learning more about 3D printing filters?
Contact an Industrial 3D printing expert to learn how you can use HP’s unique solution for 3D printing metal parts to transform the way you design and manufacture filters and other components.
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Footnotes and disclaimers
- Data courtesy of Schneider Electric
- Market Analysis Report of GrandViewresearch.
Filters Market Size, Share & Trends Analysis Report By Product (ICE, Air, Fluid Filters), By Application (Motor Vehicles, Consumer Goods, Industrial & Manufacturing, Utilities), By Region, And Segment Forecasts, 2022 – 2030.