Those who invest in additive manufacturing using metal or ceramic powders usually focus first on the printer. However, another step often determines whether the part is a success or a reject: post-processing in the furnace. Anyone considering purchasing a sintering furnace should not view the investment in isolation, but rather as part of the overall cost calculation for the entire process chain—from debinding to the final part density.

Why the Sintering Furnace Is Often Underestimated

In the binder jetting process, the sintering step significantly determines the final density, dimensional accuracy, and mechanical properties of the part—errors in the furnace process can hardly be corrected afterward. An undersized or unsuitable furnace leads to scrap, rework, or, in the worst case, discarded components after printing time has already been invested. The choice of furnace is therefore not a minor consideration, but a key factor in the cost-effectiveness of the entire production line.

Carbolite Gero: A Furnace Portfolio for Various Process Stages

With solutions such as the GLO-8/13 series, the HTK high-temperature furnaces, or the GPCMA retort furnace, Carbolite Gero covers various process stages—from gentle debinding to high-temperature sintering under inert gas or vacuum. When assessing ROI, the key factor is not so much the purchase price of a single furnace, but rather the flexibility of the platform: A furnace that accommodates multiple material classes and process atmospheres reduces the need for multiple specialized systems and, consequently, lowers investment, maintenance, and training costs.

Case Study: WZR Ceramic Solutions Expands from Ceramics to Metal AM

WZR Ceramic Solutions, based in Rheinbach, provides a clear example of this flexibility. Founded in 1996, the company has been using additive manufacturing since 2004 and initially specialized in ceramic additive manufacturing under the CerPrint® brand. With the installation of a Carbolite Gero sintering furnace, WZR is now specifically expanding its portfolio into metal AM: The furnace enables sintering-based additive manufacturing under inert gas, forming gas, and vacuum at temperatures up to 1,600 °C.

An initial project at WZR involves the production of copper components using the material extrusion process (MEX); in addition, the company expects quality improvements in binder-jetted stainless steel parts. It is noteworthy that WZR uses the same furnace platform to serve both its existing ceramics business and to tap into new metal applications—proof that investing in a versatile sintering solution pays off across multiple product lines, rather than purchasing a completely new system for each new material class.

ROI Calculation: Flexibility Instead of Parallel Investments

Applying this logic to the investment decision reveals three levers for return on investment: First, capacity utilization—a furnace that serves multiple product lines and materials operates more economically than several specialized furnaces running at partial capacity. Second, process reliability—a debinding and sintering cycle correctly designed for the respective alloy and geometry reduces scrap rates and thus material losses, which are particularly costly with metal powders. Third, scalability—companies like WZR that expand from one material class to another benefit from the fact that the existing furnace platform can scale along with them, rather than having to make new investments at every stage of development.

Added to this is an aspect that is often underestimated in investment calculations: energy efficiency. Modern sintering furnaces with optimized insulation and precisely controlled atmospheres significantly reduce energy consumption per cycle compared to older generations of equipment—in high-temperature processes up to 1,600 °C, as required for many metal and ceramic materials, this has a noticeable impact on operating costs over the lifespan of the equipment.

Binder Jetting and Sintering Furnaces: Why the Two Go Hand in Hand

In the binder jetting process in particular, the sintering furnace is not an optional accessory but an integral part of the process chain: Only through controlled debinding and subsequent sintering is the printed green part transformed into a dense, durable component. Anyone investing in a binder jetting system should therefore consider furnace selection from the very beginning—ideally with a platform that scales with increasing production volumes and new materials, rather than reaching its limits after only a short time.

Conclusion

The case of WZR Ceramic Solutions shows: A well-thought-out investment in debinding and sintering technology not only pays off during day-to-day operations but also opens up avenues for growth into new material classes. Those who view the furnace question in isolation from the overall process often underestimate its leverage on quality, scrap rates, and long-term scalability.

Before making an investment decision, it is therefore worth conducting an honest assessment: Which materials and alloys will be processed today and in the coming years, what batch sizes are realistic, and how much flexibility does the system need to accommodate future product lines? Those who address these questions early on with an experienced partner can avoid costly misinvestments and lay the foundation for a furnace solution that grows with your business over the years, rather than needing to be replaced after a short time.

Are you planning an investment in debinding and sintering technology, or would you like to expand your binder jetting setup? Talk to AM Pioneers about the right Carbolite-Gero solution for your process.

Sources

Metal AM Magazine: “WZR Ceramic Solutions installs sinter furnace for metal AM,” metal-am.com/wzr-ceramic-solutions-installs-sinter-furnace-for-metal-am/

Carbolite Gero: Additive Manufacturing Applications, carbolite-gero.com/applications/heating-applications/additive-manufacturing