German post-processing specialist Solukon, in collaboration with EOS and Sòphia High Tech, has released an industry white paper identifying powder removal in metal powder bed fusion as a critical bottleneck for part quality. While Solukon's SFM automated powder removal system can handle complex geometries, optimization during the design phase is equally important. The white paper offers several Design for Additive Manufacturing (DfAM) recommendations: adjust internal channel length/diameter, add powder escape holes, avoid rectangular or narrow channels, and optimize build orientation and support structures to facilitate gravity-assisted powder removal. The SPR-Pathfinder simulation software can pre-simulate powder flow paths to detect trapped powder zones. Additionally, a closed-loop powder recycling system improves material utilization. EOS customers have enhanced powder removal efficiency through strategies like optimized airflow management and reduced supports. The white paper emphasizes that combining automated powder removal, DfAM strategies in the design phase, and closed-loop powder management is an effective path to improve post-processing consistency and part quality.