Workflow example: Powder bed printing

In this example, we demonstrate how to implement a simple powder bed 3D printing workflow using workstations in Phasio. The workflow covers the entire production process from initial part queuing through final post-processing and quality control, providing a practical reference for manufacturers setting up similar production workflows.

Powder bed 3D printing workflow structure

This implementation creates a six-step workflow that efficiently manages powder bed printing operations while maintaining clear visibility and control over each production stage.

Workflow sequence

The example workflow consists of six sequential workstations:

1. Waiting for Nesting: Initial backlog management.
2. Printing: Active production with build preparation.
3. Post-Printing: Essential post-production processes (cooling, depowdering, etc.)
4. Black Dye: Optional finishing operations.
5. Quality Control: Final inspection and validation.
6. Completed: Workflow completion and order fulfillment.

Workstation configuration

Workstation details

Waiting for Nesting

This workstation holds the backlog of parts that have been scheduled for production.

• Uses the Basic workstation type, which has no operational effect.
• Parts are only moved out of this station—no processing occurs here.

Printing

When parts enter this workstation, the Upload 3MF step type allows manufacturers to download parts of the same material type.

• Manufacturers can download either:
  • a .camspec file for nesting software, or
  • a .zip file containing parts for local nesting preparation.
• After nesting the build from an external software, manufacturers can upload the corresponding .3mf file (exported from the nesting tool).
• The system automatically progresses the correct parts, in the right quantities, as a group into the Printing workstation.
• In the Build view type, these parts appear as consolidated builds. Manufacturers can right-click a group to rename it—for example, assigning a custom build name.

Post-Printing

Parts entering this workstation are grouped by material constraints to ensure efficient processing. The Inherit from Previous Step naming strategy retains custom group names assigned during the printing stage. This ensures consistent build identification through essential post-production steps such as cooling and sandblasting.

Black Dye

An optional finishing workstation where parts are grouped by both material and color constraints to ensure consistent dye treatment. The Inherit from Previous Step naming strategy retains group names from previous stages for continued traceability.

Quality Control

This workstation has no grouping constraints. The Inherit from Previous Step naming strategy maintains traceability by preserving group names from earlier stages throughout the final inspection and validation process.

Completed

The final stage of the workflow.

• Parts arriving here are automatically renamed with a “Finished” prefix using the Always Rename naming strategy.
• This workstation is designated as the final station (where Final Station = True), marking the completion of the production workflow.
• As parts reach this stage, the order’s completion rate progresses toward 100%. Once all parts in an order are finished, they are automatically removed from the Completed workstation.
• This station can be used to indicate open boxes or staging areas until the entire order is prepared for shipment.

Workflow operation

Part progression and filtering

When advancing parts from one workstation to the next, manufacturers can apply filters to optimize build preparation and workflow efficiency. Filters include maximum volume, customer orders, due dates, and destination workstations. This functionality is especially useful for grouping parts that share identical post-processing workflows, supporting efficient planning and resource allocation.

Scrap management

At any workstation, individual parts can be marked as scrapped due to quality issues or production errors. Manufacturers can optionally provide a scrap reason for quality tracking and schedule replacement quantities to ensure order fulfilment timelines are maintained.

Part progression flow

1. Parts automatically enter the workflow at Waiting for Nesting when an order is placed.
2. Production teams download parts grouped by material from the Printing workstation.
3. Build preparation is completed offline using nesting software.
4. 3MF upload advances the entire nested build to the Printing workstation.
5. Manufacturers manually moves parts through the remaining post-printing and post-processing stages.
6. Automatic workflow assignment allows parts to bypass the Black Dye workstation if finishing is not required.

Workflow efficiency benefits

This example illustrates how workstation configuration can significantly improve production efficiency while preserving the flexibility to meet diverse manufacturing needs and optional processing steps. Some advantages include:

• Material-based grouping minimizes error rates and reduces setup time.
• Batch processing via 3MF uploads streamlines high-volume production and simplifies build preparation.
• Flexible routing supports various customer requirements and custom workflows.
• Enables real-time tracking and visibility into part production status throughout the workflow.