What is Vapour Smoothing in 3D Printing?

With its ability to transform rough, layered surfaces into sleek, professional-grade finishes, vapour smoothing emerges as a game-changing post-processing technique in the realm of 3D printing.

As the demand for 3D printed parts grows, achieving a high-quality surface finish has become essential. Hence the importance of post-processing techniques for 3D printed objects to enhance the aesthetic and mechanical properties. By solving the common problem of visible layer lines and rough surfaces on 3D prints, vapour smoothing is an effective option for achieving professional-quality results.

Vapour smoothing is a finishing technique for 3D prints that involves exposing the printed parts to vaporised solvent. The process is also known as “chemical vapour smoothing”, “vapour polishing” or “vapour fusion”, and helps eliminate the sugar cube-like finishes and the unsightly layer lines often associated with 3D prints.

The chemical vapours used in the process react with the material's surface, causing it to melt and partially dissolve, resulting in a smoother finish. By using this technique, 3D printed parts can get a smooth and glossy surface that looks more professional.

Vapour smoothing can be seen as an excellent finishing option that adds significant value to 3D printing. The technique is widely used in the automotive and aerospace industries, where parts must be as smooth and perfect as possible for optimal function and aesthetics.

Vapour smoothing is a highly effective and efficient way to achieve smooth surface finishes on various materials without any material removal. It employs a finishing agent and controlled chemical melt to achieve the desired outcome. Maintaining proper temperature and pressure control during the process is essential to achieve the desired outcome while avoiding any damage to the workpiece.

Here is a step-by-step guide on how a fully automated smoothing process works:

Vapour smoothing is extensively used across various 3D printing technologies, polymers and elastomers. The technique can be applied to a vast range of 3D printing materials, with the most commonly used ones being PA 12 and PA 11. The vapour fusing post-processing technique can be combined with dyeing in order to achieve a part with a smooth and coloured surface.

3D printing has revolutionised manufacturing, enabling the production of complex parts with intricate geometries. However, as the technology evolved, improving the surface finish of printed parts remained a challenge. That's where this post-processing technique significantly enhances the surface of 3D printed parts. Its major benefits are listed below.

Compared to standard SLS parts, which typically have a surface roughness greater than 8 μm Ra, chemical vapour smoothing can achieve a surface finish below the 3 μm Ra threshold.

An improved surface finish considerably impacts the mechanical performance of a printed part. When it comes to additive manufacturing, surface roughness directly affects the part's tensile strength, elongation at break, and flexural performance. Whereas a poor surface finish can create stress concentrations and reduce the part's fatigue life, causing the part to fail prematurely.

This surface finish significantly reduces the moisture absorption of the part's surface. Moisture can lead to the degradation of the part and affect its mechanical properties. By sealing the part's surface, vapour smoothing prevents moisture absorption, making the printed part more durable.

One of the most significant advantages of this process is its ability to polish non-line-of-sight features. The technique can reach deep recesses and internal cavities inaccessible to traditional polishing or sanding methods. Therefore, parts with complex geometries can still achieve a high-quality surface finish.

Vapour smoothing preserves the printed part's geometries and dimensional accuracy while enhancing its surface finish. Unlike traditional machining or sanding processes, which can deform or modify the printed part's dimensions, vapour polishing is non-abrasive and maintains the part's original shape. This is especially important for high-precision parts that require strict dimensional tolerances.

When designing CAD files for parts that will be vapour smoothed after printing, you should keep specific design tips in mind. Take a look at these guidelines to ensure your parts turn out beautifully and with a perfect finish.

Vapour polishing is a robust finishing process that can significantly enhance the performance and aesthetics of 3D prints. Some applications where this technique can be used to create superior, end-use parts are as follow:

Vapour smoothing is a highly effective and efficient technique for finishing 3D printed parts that eliminate visible layer lines and improve surface roughness. With its ability to preserve the part's original features and geometries, it is an excellent solution for parts with complex geometries that require strict dimensional tolerances.

Xometry offers vapour smoothing capabilities for 3D printing and other supplementary services to cater to all your prototyping and production requirements. Upload your CAD files and get an instant quote for your 3D prints.

1 August 2023

06:00