How Vapor Smoothing Post-Processing Enhances the Surface Quality of SLS and MJF Parts
At Graphite Additive Manufacturing, we pride ourselves on delivering high-performance 3D-printed parts for industries, where strength, precision, and surface finish are critical.
To enhance the functionality and aesthetics of our components, we utilise advanced post-processing techniques, including the PostPro® Vapor Smoothing technology from AMT (Additive Manufacturing Technologies). This process is particularly effective on components printed in SLS (Selective Laser Sintering) using our exclusive SinterWorx G4 and C6 materials, as well as MJF (Multi Jet Fusion) PA12.
Let’s dive straight into how Vapor smoothing transforms part surfaces, unlocking new performance advantages across the board.
Vapor Smoothing – a game-changer for functional parts
Vapor smoothing is a post-processing technique that enhances the surface quality and performance of 3D-printed polymer parts. It works by chemically smoothing the surface, significantly reducing surface roughness, sealing pores, and creating a smooth, glossy finish – comparable to injection-molded components.
The process is especially beneficial for SLS materials, which are inherently porous right off the build platform. The vapor smoothing process seals these pores, transforming the surface into a continuous, non-porous layer.
How Does Vapor Smoothing Work?
The process involves placing parts into a controlled chamber, where they are exposed to a vaporised solvent. This solvent condenses onto the surface of the parts, lightly melting and reflowing the material’s outermost layer.
Surface Redistribution:
The vapor reacts with the outermost layer of the material, melting it slightly. This redistributes the surface material to fill in porosity, eliminate layer lines, and create a sealed surface.
Uniform Smoothing:
The process is non-line-of-sight, meaning it is possible to evenly smooth complex geometries, including internal cavities and intricate features.
Temperature Differential:
The process works by utilising the difference in temperature between the printed part and the temperature of the chamber. This temperature difference allows the atomised solvent to condense on the surfaces of the part. This is why a minimum wall thickness of 1.5mm is required as wall thickness below this do not have enough mass to retain the temperature difference required.
The final result is a smooth, sealed surface that improves both form and function and is generally visually attractive.
Key Benefits of Vapor Smoothing
- Pore Sealing: SLS materials are naturally porous, which can limit their functionality in certain applications. Vapor smoothing creates a sealed, non-porous surface, allowing parts to hold pressure, resist fluid penetration, and maintain airtightness.
- Superior Finish: The process reduces surface roughness to less than 1μm Ra, comparable to injection-molded parts. This improved finish minimises friction, enhances aesthetics, and simplifies cleaning.
- Improved Mechanical Properties: By eliminating surface porosity and crack initiation points, vapor smoothing improves elongation at break and fatigue resistance, making parts more durable under stress.
- Water Resistance: The sealed surface prevents moisture absorption and deflects water, making parts suitable for humid or wet environments.
- Pressure Retention: With a sealed surface, vapor-smoothed parts can reliably hold air and fluids, making them ideal for applications such as air ducts, fluid connectors, and pressurised components.
- Enhanced Colour and Gloss: The process enhances the visual appeal of parts with customisable gloss levels and improved colour saturation. Especially notable for MJF PA12 parts – a dyed-like black finish can be achieved in one step.
- Retention of Fine Details: Vapor smoothing preserves intricate geometries and delicate structures, ensuring accuracy and fidelity to the original design.
- Reduced Post-Processing Time: A faster, cost-effective alternative to manual finishing or painting.
Applications Across Key Industries
This technology opens up new possibilities where performance and aesthetics go hand in hand:
- Motorsport: Gearbox baffles, brackets wiring loom guides, enclosures, inlet plenums and air ducts.
- Aerospace & Automotive: Jigs, tools, enclosures, internal and external aesthetic components.
- Medical Devices: Smooth, non-porous surfaces that are easy to sterilize and hygienic.
- Consumer Products: High-quality professional finishes for functional and aesthetic applications.
- Industrial Equipment: Airtight housings, fluid connectors, and other pressure-sensitive components.
- Marine: Corrosion-resistant parts, sealed enclosures, and functional components for harsh environments.
So why Graphite Additive Manufacturing and AMT PostPro® Vapor Smoothing technology?
At Graphite Additive Manufacturing, we bring together deep expertise in additive manufacturing and the latest in post-processing innovation. One standout technology in our portfolio is AMT’s PostPro® Vapor Smoothing, a high-end finishing process designed to elevate both the performance and appearance of 3D-printed parts.
“At Graphite Additive Manufacturing, we combine our expertise in additive manufacturing with cutting-edge post-processing technologies like vapor smoothing.
Vapor smoothing adds to our suite of finishing options, specifically tailored to motorsport and automotive applications. This is a very complementary technology for us, and fits in perfectly with our business. We are proud to offer AMT’s PostPro® Vapor Smoothing process, giving our clients direct access to one of the most advanced post-processing solutions available today.”
Kevin Lambourne, Managing Director, Graphite AM
The Power of Partnership: AMT on Working with Graphite AM
“Working with Graphite Additive Manufacturing has been a great example of how advanced post-processing can unlock the full potential of additive materials.
Their graphite-infused nylon material delivers impressive mechanical properties, and by applying our PostPro® Vapor smoothing technology, the team at Graphite AM have been able to further enhance the surface quality and durability of their 3D-printed parts, making the material even more suited to demanding end-use applications. It’s a pleasure supporting their mission to further push the boundaries of industrial 3D printing.”
Giorgio Ioannides, Global Head of Sales, AMT PostPro
Unlock Performance Through Precision Finishing
Whether you’re producing functional components for high-performance environments or aesthetically refined parts for customer-facing applications, our vapor smoothing service delivers exceptional results, combining strength, precision, and visual appeal.
Ready to Elevate Your Parts?
Discover how vapor smoothing can enhance your 3D-printed designs and deliver a superior end-use experience.
