Zac is a Process Manufacturing Engineer with expertise in additive manufacturing post-processing and inspection. He focuses on strengthening operational efficiency through continuous improvement and the development of new processes, ensuring systems are efficient, reliable, and repeatable. His work includes driving modernization initiatives that enhance productivity and cost efficiency across manufacturing operations. Zac earned his degree in Business & Engineering from Drexel University and is dedicated to advancing post-print operations to enable consistent, production-ready outcomes.
When designing for additive manufacturing, the finish of a 3D printed part often dictates whether it can truly transition from a prototype to an end-use component. The matte, slightly rough texture of a nylon part can limit their performance and aesthetic appeal in customer-facing products. At Stratasys Direct, we understand that for AM to compete with traditional manufacturing methods like injection molding, the quality and finish sometimes matters as much as the accuracy of the print.
That’s why we’ve integrated vapor smoothing into our in-house post-processing capabilities. This allows us to offer a finish that not only dramatically improves the appearance of PBF parts, but also fortifies their functional performance, making them ready for the most demanding real-world applications.
Vapor smoothing is an advanced post-processing technique that dramatically enhances the surface quality of thermoplastic 3D printed parts. The process involves heating the parts and exposing them to a controlled chemical vapor. As the vapor condenses on the surface, it gently melts the outermost layer—causing peaks and valleys to level out and pores to seal resulting in a smooth, semi-gloss finish that looks and feels like injection-molded plastic without compromising part accuracy or strength. It’s a chemical treatment that transforms the surface texture, eliminating the characteristic layer lines and roughness of additive manufacturing.
Vapor smoothing offers key advantages that push additive parts from prototypes into production-ready parts.
1. Smooth Surfaces with Dimensional Accuracy
The process only affects the outermost layer, averaging out surface roughness while preserving the part’s original geometry and tolerances. Unlike mechanical smoothing methods, which uses physical abrasion and material removal, vapor smoothing minimizes impact on the part’s critical dimensions and internal features.
2. Sealed Surfaces for Water & Air Tightness
Vapor smoothing creates a continuous, sealed surface—ideal for applications requiring improved environmental resistance or fluid containment. This sealing action makes parts less porous, increasing their resistance to moisture, oils, and chemicals, and is essential for components used in fluidics or outdoor environments.
3. Enhanced Color and Appearance
Many powders bed fusion (PBF) materials, especially greyscale nylons like PA12, darken during smoothing. This can improve dyeing results or even eliminate the need for dyeing altogether, saving time and cost. The sealed, uniform surface also accepts dyes and paints much better, leading to richer, more vibrant final colors and a professional aesthetic.
To support our new vapor smoothing service, SDM has invested in the AMT PostPro SF100, a production-grade system engineered for high-throughput additive manufacturing environments. This advanced platform features a 100-liter process chamber and is optimized for smoothing a wide range of thermoplastic materials commonly used in additive manufacturing. With this investment, SDM is equipped to deliver high-quality production ready finishes at scale, helping customers achieve smoother, stronger, and more visually refined parts.
The addition of vapor smoothing is a direct response to our customers’ need for scalable, end-use parts. By investing in industrial-grade vapor smoothing capabilities, we close the gap between the speed of AM and the high aesthetic and performance standards of injection molding. Vapor smoothing allows for a repeatable, validated process that can handle large volumes of parts, while maintaining tight quality control and traceability. The addition of vapor smoothing ensures that we can deliver high-quality, production-ready finishes at scale, helping our customers achieve smoother, stronger, and more visually- pleasing parts without adding costly, time=consuming manual post processing steps.
At Stratasys Direct, part quality goes beyond appearance. It includes safety, reliability, and peace of mind. That’s why our vapor smoothing process uses PostPro Pure, a solvent that meets rigorous health and environmental standards.
Parts processed with PostPro Pure have been tested for skin contact and cytotoxicity, confirming they are safe to handle and use. The solvent is non-toxic, non-sensitizing, and approved for use in food-contact and medical applications under FDA and EU regulations.
In addition to being safe for users, PostPro Pure is also environmentally responsible. It is readily biodegradable and has shown no harmful effects on aquatic life, making it a smart choice for sustainable manufacturing.
Interested in learning how vapor smoothing can enhance your next project? Our team is ready to support your goals with expert guidance and fast, reliable service.
