_ Finishing processes
Precision finishing
More and more demanding quality standards on the market are dramatically increasing the importance of precision surface finishing processes. These treatments improve the aesthetic appearance of metal parts, but also their mechanical and physical characteristics, corrosion resistance and lifespan, among others.

Smoothing
Processes related to smoothing metal surface allow to achieve uniformity of product for appearance’s sake, and to be safe for touching without being scratched to shreds by unfinished roughness. For moving parts, a smooth finish cuts down on friction loss, without getting into coatings.

Mirror finishing
A mirror finish is a highly-polished finish, characterized by a bright, shiny, reflective metal surface. A high-quality mirror finish is not only visually appealing, but the gradual removal of surface scratches reduces indentations or grooves on metal, which may contain contaminants, such as dirt or bacteria.

Deburring
Deburring is a material modification process that increases the final quality of the product by removing impurities with a negative impact the on the appearance of a smooth machined surface, like sharp edges or burrs, left by bending, cutting, piercing, shearing and compressing materials.

Rounding
Rounding cutting edges is crucial for the design and geometry of cutting tools in metal machining. Cutting edge geometry determines the thermo-mechanical stresses on the tool. By employing edge preparation, tool life, cutting performance, and the quality of the machined surface can be improved.

Corrosion resistance

AM Post-processing
Surface roughness of AM parts can vary depending on the technology used and parameters applied, and affects fatigue, corrosion resistance and friction properties. In order to improve the surface quality, electropolishing is postulated as the most promising the treatment to reduce roughness and defects.

Inner channels
Surface quality requirements of internal surfaces, inner channels and complex parts with blind holes have increased during the last years specially in case of injection molding, aerospace, automotive, medical, food and pharma, semiconductors and gas and fluid flow applications.

_ Industries
Aerospace
Surface finishing operations play an extremely important role in aerospace and energy sectors, since it helps to improve efficiency, while increasing reliability and durability. These parts must withstand high stress corrosive conditions, high loads with long-term lifespan and meeting demanding cycle life specifications.

Automotive
Surface finishing solutions are utilized at every level of the automotive pipeline, from garage maintenance and car restoration to manufacturers’ demands. One of the most challenging aspects has to do with safety, since the result of the surface finishing process is closely linked to the vehicle performance and reliability.

Dentistry
Dental laboratories use dry electropolishing to improve surface quality of cobalt-chrome and titanium dental parts. Smoothing, cleaning and eliminating small imperfections from removal dental prosthetics and other implanted dental parts expands their lifespan pieces and can extend the life of dental components from the inside out.

Food & Pharma
Metal components produced for food, beverages, packaging and pharma industries must comply with challenging surface finishing standards. Those surfaces should be ultra-smooth, precision finishing, thus avoiding areas for bacteria grow. DLyte achieves superior results than any other surface finishing method.

Jewelry & Fashion
These industries require a perfect surface quality as the purpose of the piece is mainly aesthetic and its value depends on a good looking. Complex geometries in jewels are hard to polish with traditional polishing methods and electropolishing is one of the techniques utilized for a better homogeneity and standardization.

Medical device
Cleanability, biocompatibility, corrosion resistance, pathogen resistance and a smooth surface without defects are crucial to comply with the function and demand on quality of the medical industries. Improving the surface’s quality on implants, instruments and equipment components increases functionalities as well as their lifespan.

Toolmaking
Overcoming the drawbacks of tool finishing is one of the main challenges in the field of surface finishing solutions, in order to achieve the lowest roughness on flat surfaces. This is why DLyte has specially created new electropolishing technologies to carry out the most challenging freeform surfaces polishing.

_ Technologies
Immersion
DryLyte is a patented technology for grinding and polishing metals by ion transport using free solid bodies. It works by combining the electrical flow created by high-precision rectifier. This results in an ion exchange, removing material from the peaks of roughness.
Projection
Our new Electro-Blasting technology, released in 2021, is a new solution that provides a stream of solid-electrolyte particles propelled by a non-conductive liquid media to improve the surface quality. The media is projected towards a localized area of the piece.
_ Industrial solutions
_ Dental solutions
Desktop series
Accessible to small laboratories, workshops, workrooms and SMEs needing a cost-effective solution for metal surface finishing processes. From grinding to mirror finishing, this new set-up offers a new easy way to process any casting, sintering or milling metal parts.

Compact series
An efficient range of solutions to meet the requirements of dental, medical and industrial sectors, depending on finishing needs, production quantities or part dimensions. Ensures high scalability and performance. A solution for the most common metals and alloys.

PRO500 series
The most advanced, powerful and versatile surface-finishing machine for mass production on the market. It performs high-quality metal surface-finishing better, faster and more efficiently with processing times ten times better than current technologies.

DLyte 10,000
The most powerful modular unit for polishing large, heavy and complex pieces to be totally integrated in any production line. The robot module allows to treat metals and alloys in a fast, and cost-efficient way. It counts with a precise 6-axis mechanical movement.

DLyte eBlast
Projected dry electropolishing for focused surface finishing in complex geometries and heavy or large parts. It provides a stream of solid-electrolyte particles propelled by a non-conductive liquid media to achieve the best surface quality results of metal parts.

Dental series
An efficient range of solutions to meet the requirements of dental sectors, depending on finishing needs, production quantities or part dimensions. Ensures high scalability and performance. A solution for the most common metals and alloys.

DLyte Mini
It is perfect for low production volumes or as a complementary device to existing DLyte equipment. It can be used as a secondary, quick-step process to achieve a superior shine.

Consumables
A perfect surface requires the right combination of DLyte machine, DLyte electrolyte media and finishing process parameters. We have a wide range of DLyte electrolyte media to ensure your workpieces look exactly how you want after processing.

Services
DLyte offers a comprehensive solution combining knowledge, tools, programming, and support to integrate DLyte into your production chain seamlessly. We are dedicated to delivering customized experiences and ensuring your success with DLyte.

_ Comms
News
Find out more about our corporate news, the latest commercial developments and upcoming events. From the main international trade shows to the most innovative launches, we invite you to learn more about GPAINNOVA’s brand DLyte. Stay tuned for all the projects in which we are involved!

Exhibitions
Our aim is to be as close as possible to our customers. This is why GPAINNOVA attends every year more than 40 international trade shows dedicated to the dental, healthcare, and industrial sector, including key events such as Formnext or EMO Milano. Check all our upcoming events here!

Webinars
Innovation is in our DNA. Our business group is continuously investing and focusing on getting better to meet the real needs and demands of the industry, which are increasingly changing. Do not miss them out! Learn more about our newest technological developments: machines, fixturing, electrolyte and much more.

Media
Would you like to see how our machines and our disruptive DryLyte Technology work? Do you want to know how they can help you automate your surface finishing processes and make them more cost-efficient and environmentally-friendly? Take a look at our video gallery and find out more about our machinery!

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History
Created to overcome these challenges, DryLyte is the basis of DLyte, a technological system that automates, simplifies, and standardizes the post-processing of metal parts. It provides a high-performance solution for the most demanding metals and alloys in the industry.

Awards
GPAINNOVA is a technological platform based on the design and implementation of multidisciplinary innovative projects. Multiple brands within the group have received prestigious national and international awards and recognitions within a short period of time since GPAINNOVA was founded.

Schedule a visit
Our technology knows no borders. Neither does our team! Our DLyte on Tour regularly visits companies across Europe for free, to showcase at home our most advanced solutions for surface finishing in metal parts. Are you interested in an in-house demo at no cost?

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Disruptive surface
DLyte is a surface finishing system for metal parts requiring high performance or superior finishing. DLyte equipment uses the novel DryLyte Technology which brings significant technical advantages over competing technologies, such as abrasive finishing, robotic grinding and polishing, mechanical brush and grinding systems. In addition, it achieves a quality equivalent to manual grinding and polishing automated, fast and cost-effectively.
Unlike traditional surface finishing systems, the DLyte system obtains consistent finish, avoiding any marks on the surface or patterns and is able to process complex geometries without generating micro scratches on the surface and preserving the geometry. DLyte respects the tolerances of the piece, delivering a mirror finish.


DryLyte Technology process
DryLyte is a patented technology for grinding, polishing, deburring and rounding metals by ion transport using free solid bodies. This new technology based on a set of solid electrolyte particles with the ability to conduct electricity and to remove the oxides produced during the electropolishing process.
The DryLyte Technology works by combining the electrical flow created by high-precision rectifier with the movement of the pieces through the electropolishing media. This results in an ion exchange, removing material only from the peaks of roughness. The process does not round edges and can access corners that are not easily accessed mechanically.



The media used is formed by a set of spheres of non-conductive polymeric material that is capable of retaining liquid electrolyte without it being able to escape. When contacting a surface, the sphere can only contact the peaks of roughness, and it is only at these contact points that the oxidation and removal of material occurs.
In this way, the finishing is highly selective, and is better able to maintain the geometry of the piece. This selectivity allows dry electropolishing to achieve the same roughness reduction as liquid electropolishing while removing less metal overall.
“The process extracts the material only from the peaks
of the roughness, it does not round the edges but
penetrates the internal cavities of the piece to which
cannot be accessed mechanically.”
Comparison vs liquid electropolishing
and abrasive finishing
LIQUID ELECTROPOLISHING
+ All surfaces contact liquid
+ General oxidation
+ Low discrimination
DRYLYTE TECHNOLOGY
+ Spheres contact on roughness peaks
+ Localized oxidation
+ Selective removal of metal
+ Geometry preservation
+ Improved corrosion resistance
ABRASIVE FINISHING
+ Plastic deformation of roughness peaks
+ Inclusion of broken abrasive
+ No improved resistance to corrosion
+ Rounding of peaks and geometry harm
-
LIQUID ELECTROPOLISHINGDRY ELECTROPOLISHINGABRASIVE FINISHINGJust polishing in one stepGrinding + polishing in one step (macro and microscopic finishing)Several steps required to perform grinding and polishingNo selective grinding: the electrolyte impacts on the valleys' surface)It improves surfaces selectively, layer by layer, using polymeric particles with a larger diameter than the roughness profile (avoiding the electrolyte's impact on the valleys' surface)--More than 5 times quicker than mechanical abrasive finishingLong-lasting processes-It does not round the edges of the pieces and preserves their geometryIt rounds the edges of the metal parts, since the system is based on applying pressure and movement with abrasive media-Suitable to treat small corners and dead zonesNot recommended for small corners and dead zones, since it is not able to apply pressure and movement with accuracy-It makes visible design flaws and material porosity, since DryLyte removes material by ion transport makingIt causes plastic deformation of peaks, which can hide design flaws and material porosity-Suitable for fragile parts, as the media does not apply mechanical forces to the workpiecesIt may damage fragile parts, as the surface improvement is done by the application of mechanical forces-Parts can be treated partially, by not applying electrical conductivity or covering a specific area of the piece, which protects the required areasIt requires the use of very hard materials to protect the areas which requires no treatment-It achieves clean, inert, and biocompatible surfacesIt may cause broken abrasives inclusions on the surface, which requires a cleaning step-Suitable for inner channels, by the application of internal cathodes which allow direct electrical conductivity through these channelsNot suitable for inner channels<50% roughness reduction without modifing geometriesIt achieves lower surface roughness (<80% roughness reduction, with low material removal and no patterns on the surface)It generates scratches on the surfaceSide effects (oxidation, passivation, milky surface & orange peel)No side effects (oxidation, passivation, milky surface & orange peel)-Non homogeneus results (since the polishing liquid takes a straight way along the surface)Homogeneous results, as the current flows through the media randomly; this reduces differences in current density within the piece surface features-Not suitable for all alloysSuitable for any metal alloy, including cemented carbide (the process time is not affected by the hardness of the material)-It increses corrosion resistance, but to a lesser extent than dry electropolishingIt increases corrosion resistance up to 4 times comparted to liquid electropolishing, while improving the parts' surface-
-
LIQUID ELECTROPOLISHINGDRY ELECTROPOLISHINGABRASIVEParameter adjustments for different surface areas are requiredIt does not require adjustments based on the surface to treatIt requires adjustment and maintenance of the media and partially replacement of it to keep the performance within the lifespanMaterial removal is difficult to control for pieces with tight tolerances, as it is aggressive in terms of material removal per minuteControlled and homogeneous results, since it is adjustable in terms of material removal per minute.-It may generate sludge, which requires to be removed from the tanks and cathodes to keep the process stableNo need of electrolyte adjustment or maintenance, as it is performed automatically by the equipment; the metal removed from the work pieces remains in the media-It needs replacement of a portion of the used solution for a good performance and to guarantee a high-quality metal surface finishing processHigh-quality surface finishing within the whole lifespan of the media, which is replaced completely after its use.--No need of peripheral equipment to treat partsIt requires waste water cleaning and recirculating systems and sludge treatment equipment-No need to change the media within the processIt is necessary to change of the media and further handling of parts, since it involves several steps
-
LIQUID ELECTROPOLISHINGDRY ELECTROPOLISHINGABRASIVEHighly-corrosive and toxic liquid mixtures of phosphoric and sulphuric acids. This may be dangerous for professionals during handling.Electrolyte media with very low acid concentration, which can be handled and stored without additional safety measuresIt usually requires compound and chemical accelerators in large amounts, which involves a danger for workers during handlingHigh risk for workers in case of accidental splashes, as the liquids are corrosives at high temperaturesNo risk of accidental splashes, since the media is solid at low temperature-Handling and maintenance of the tank and the cathode cleaning operation involves risks for the workers, as metals removed from the work pieces remain in the liquid and partially attached to the cathodeWorkers are not exposed to the cathode, since metal removed from the work pieces remains in the mediaHandling of sludge and compounds with high concentration of metals may be also harmful for workers if protective measures are not strictly ensuredIt may require specific safety measures because of gas filtering, to protect human health and environmentDryLyte volatile organic compounds (VOC) are very low, thus requiring no specific safety measures and far below the limits to be dangerous for human health or environment--It does not generate dust during the processIt generates dust, which can be dangerous for the health, since the particles that cause damage are often invisible to the naked eye; this is why the eventual health effects of exposure can take many years to be visible-Silent processThe proceess is usually very noisy and can lead to hearing loss in case of inadequate hearing protection or prolonged exposure to noise in the workplace-No need of additional manual finishing stepsIt may require in some cases a final manual buffing to achieve the required surface quality, which involves an additional exposure to dust and toxic particles to workers-Cleaning method based on a soft ultrasonic or steamer process to remove the electrolyte that remains on the surface of the pieceIt requires a complex cleaning process involving toxics to remove any abrasive, oil or other products that remain on the surface of the piece
-
LIQUID ELECTROPOLISHINGDRY ELECTROPOLISHINGABRASIVEIt requires additional safety measures to be put in place for proper disposal, due to environmental concerns related to highly corrosive and toxic mixtures of phosphoric and sulfuric acids and sludges containing metalsNo additional safety measures required, due to the low acid concentration in the electrolyteIt requires compound and chemical accelerators in large amounts, which involves an eventual risk of discharge into the environmentThe post-dip can cause a discharge in waterways or drainsThe handling of the electrolyte reduces the probability of discharge in drains and waterwaysLiquids used in liquid electropolishing and in the post-dip can cause a discharge in waterways or drainsSludges and liquids need to be treated by specific services to ensure environmental compliance conforming to regulations.The waste generated can be handled by standard waste management servicesSludges and liquids need to be treated by specific services to ensure environmental compliance conforming to regulations-Low water consumption, as it only needs water to adjust conductivity of the mediaLarge amounts of water are generally necessary to finish, especially for high quality surface finishing requirements; if different materials are processed in the same media, a heavy flow of water is required to prevent pollution
-
LIQUID ELECTROPOLISHINGDRY ELECTROPOLISHINGABRASIVEIt usually requires previous steps to finish the workpieces completely, as well as peripheral equipment to store and treat sludges and liquidsIt replaces several finishing steps, including the corrosion resistance improvement in just one compact equipmentIt requires several steps to finish the workpieces completely, as well as peripheral equipment to treat water and sludges and an isolated plant to improve corrosion resistanceIt requires to be isolated and to put in place specific safety and regulatory measuresThere is no need of an isolated plant to process parts, with the consequent reduction of required space in the factory-It requires replacement and deep cleaning of the tanks to process different materialsIt achieves quick an optimal ROI and major savings for high-end applications requiring defect free surfaces (it can process different materials in the same equipment just replacing the media)It may have some hidden costs including high scrapping ratio-5 times quicker than abrasive finishing with the consequent reduction of required space in the factoryLong-lasting processes
The DryLyte Technology offers a wide range of finishing media. The consumables, designed and developed in our test lab, allow us to precisely meet our customers’ requirements.

DLyte achieves homogeneous results across the surface and eliminates micro scratches, as opposed to abrasive polishing. The system works efficiently at a micro and macroscopic level.

Respects the tolerances and preserves the initial shape, even the edges, guaranteeing the most precise result. It does not round the edges as there is no mechanical abrasion of the surface.

Reduces the roughness over 80% avoiding undesired effects. Liquid electropolishing is not able to reduce the roughness more than 50% without generating side effects like orange peel or pitting.

Removes material only from roughness peaks as the diameter of the particles is bigger than the roughness profile. It penetrates internal cavities that cannot be accessed mechanically.

The DryLyte Technology ensures stable results among various batches along the electrolyte media lifespan. There is no physical wear, as would typically occur with abrasive particles.

DLyte increases the surface bearing contact area allowing uniform lubricant film distribution and improving the bearing ratio and reducing the friction between the pieces.

Reduces wear and improves fracture and fatigue strength, while improving the surface quality of metal parts. It also removes embedded free iron, contaminants and heat tint or oxide scale.

Uses only polymer particles with acids for surface improvement. It ensures that the parts meet all the appropriate requirements to pass a risk-benefit analysis evaluating biocompatibility and toxicity.

This is the only technology that allows to remove roughness and improve the corrosion resistance of the metal pieces while reducing the number of processes required in the manufacturing process.
DLyte solutions consist of three different
typologies based on DryLyte technology,
divided into two types of systems.
Immersion systems
Surface finishing processes by immersion are carried out by placing the metal pieces to be treated in a working bowl or tank filled with electrolytic media, consisting of solid bodies that completely cover the parts. The consumable material chosen may be of different types, depending on the results sought. For this purpose, different kinds of consumable are used: dry polymeric particles without any additive or polymer particles mixed with a moderator liquid that enhances final brightness.
The consumable reduces the surface roughness without impacting on the original geometry, since the metal removal is based on ion transport instead of abrasion of the surface. DLyte’s equipment uses electricity with specific electrical parameters and moves the parts fixed by fixtures inside a bowl full of media. Every time an electrolyte particle impacts the metal surface, there is an ion transport that removes irregularities from the peaks of the surface.
Dry
Dry surface finishing is a patented technology for grinding and polishing metals by ion transport using free solid bodies. This system is based on solid media with no liquid added.
It works by combining the electrical flow created by the high-precision rectifier with the movement of the pieces through the electropolishing media. This results in an ion exchange, removing material only from the peaks of roughness.
How it Works
It is based on dry solid particles for immersion systems. These bodies collide with each other, starting an ion exchange and removing the outer layer of the metal part, to eliminate imperfections on the metal piece.
Dry Surface Finishing’s Benefits
+ Faster surface finishing processes.
+ Easiest to manage.
+ For simple geometries.
Dry Suspension
Dry Suspension is a revolutionary solution based on a new electrolyte that combines polymer particles and a moderator liquid, especially designed to improve the results of conventional dry electropolishing processes.
How it Works
The Dry Suspension consumable consists in a mixture of solid particles and liquid for immersion systems. These free bodies collide into each other, starting an electrolysis process that eliminates imperfections on the surface. The moderator liquid improves the final gloss of the part.
Dry Surface Finishing’s Benefits
+ For complex geometries.
+ Shiniest results.
+ Part protected by the liquid: minimizes undesired
oxidation and reduces the contact surface.
Projection systems
The Dry Projection technology, released to be used in the DLyte eBlast machine, is a new solution that provides a stream of solid-electrolyte particles propelled by a moderator liquid media to improve the surface quality. The media is projected towards a localized area of the piece.
In comparison to liquid electropolishing, this moderator liquid is not directly involved in the surface finishing process. Its main function is carrying the particles; its specifically developed composition contributes to maintain the connectivity and conductivity between particles during the process. Additionally, this liquid creates a protective layer over the metal surface, accumulating especially in roughness valleys, thus protecting the surface from pitting.
Electro-Blasting
This new projected electropolishing opens up a wide range of possibilities for the treatment of metal surfaces with non-homogeneous roughness or complex geometries (the current main obstacle of AM parts), as well as large, heavy pieces. This feature can provide finishing solutions in sectors such as 3D printing, automobile industry, railway and specially injection molds.
How it works
The Dry Suspension system is based on a mixture of solid particles and liquid for projection systems.
Particles collide with each other through the liquid emulsion which, when agitated, becomes conductive.
Dry suspension’s benefits
+ Higher adaptability and customization.
+ For complex geometries.
+ Part protected by the liquid.
How to know which
technology meets your needs
Our surface finishing experts provide guidance about the technology and system that better suit to your surface finishing challenge. Those are some of the key factors which need to be taken into account for a successful choice:

The material being treated is a crucial factor in determining the appropriate electrolyte formulation and process parameters. At our test lab, we have developed consumables that enable us to precisely meet the requirements of our customers. There are many factors that must be considered when treating a material, such as its composition, density, and hardness. Our team of experts has extensive knowledge of various metals and alloys and can determine the best electrolyte formulation and process parameters for each material.

Every part is unique, and achieving the desired surface finish requires a customized approach. That’s why we begin our projects by closely collaborating with our clients, evaluating their goals for their pieces, as well as the initial part condition and manufacturing process. Using our extensive expertise, we define the optimal process parameters, media formula, and geometry that will deliver the perfect solution. This meticulous attention to detail is what sets us apart and ensures that our customers always receive the best possible outcome.

Our equipment uses mechanical movements and electrical parameters to ensure optimal media and electricity flow across the surface, achieving homogeneity on the part. The DLyte systems can process parts of various geometries, shapes, and sizes with precision. Our equipment is designed to provide precise and uniform results, regardless of the shape or size of the part being treated. Our immersion and projection systems are highly versatile and can meet the surface finishing needs of a wide range of industries and applications.