Engineers and innovators consistently push the boundaries of what additive manufacturing can achieve. We share that vision. By collaborating on complex geometries, we help development teams produce functional, durable components directly from digital files.

However, when a project requires parts to hold liquids or gases under pressure, standard Selective Laser Sintering (SLS) and Multi Jet Fusion (MJF) methods often present a hurdle. The inherent nature of powder-bed fusion creates microscopic voids. To achieve true liquid-tight performance, device-makers need a reliable post-processing partner. Vapor smoothing bridges this gap, transforming porous printed shapes into fully sealed, production-ready components.

Understanding Porosity in SLS and MJF Processes

To see why untreated 3D printed parts leak, we must look at how they are built. Both SLS and MJF construct parts layer by layer using thermoplastic powders, such as durable nylons. A precise heat source melts the powder particles together to form the desired shape.

While this creates strong mechanical bonds, the fusion leaves microscopic air pockets trapped between the particles. This results in a naturally porous internal structure. When you introduce fluid or pressurized air to the inside of an untreated part, the fluid finds its way through this microscopic maze and eventually weeps out the other side. Overcoming this physical limitation is essential for creating high-performance, fluid-handling parts.

How Vapor Smoothing Works

Vapor smoothing is a highly controlled chemical treatment designed to alter the surface of the plastic. Instead of applying a separate coating that might chip over time, vapor smoothing physically melts and reforms the exterior of the part.

The chemical solvent briefly liquefies the outermost layer of the thermoplastic, flowing smoothly to fill in the microscopic pores. Once cured, the plastic hardens into a continuous, non-porous skin.

At Shapeways, we proudly offer advanced vapor smoothing capabilities using the state-of-the-art AMT SF100 machine. This innovative equipment boasts an impressive processing volume of 40cm by 40cm by 60cm. This significant capacity allows us to efficiently handle a wide range of model sizes and batch quantities, ensuring repeatable, reliable quality for your production runs.

Collaborative Engineering: Tanks, Manifolds, and Ducting

Achieving a leak-proof seal opens up entirely new applications for digital manufacturing. We partner with engineers to design and manufacture complex fluid-handling components without the need for secondary sealing operations like epoxy dipping.

  • Fluid Tanks and Reservoirs: Custom fluid reservoirs often require unusual shapes to fit into tight automotive or aerospace assemblies. Vapor smoothing ensures these custom tanks securely hold coolants, oils, or water without seepage, even during continuous use.
  • Hydraulic and Pneumatic Manifolds: Manifolds direct the flow of liquids or gases through complex networks. Vapor smoothing reaches deep into internal pathways, sealing the walls to prevent pressure drops and cross-channel leaks.
  • Complex Ducting: Airflow and ventilation systems rely on airtight seals to maintain optimal efficiency. Vapor smoothed ducting prevents pressurized air from escaping, while the smoothed internal surfaces reduce friction for excellent flow dynamics.

Benefits of Vapor Smoothing

The advantages of our chemical treatment process extend well beyond functional fluid containment. Vapor smoothing significantly enhances the material properties of your parts, elevating both performance and presentation.

  • Water Resistance: The process renders the models highly water-resistant, expanding their potential applications and longevity in various environmental conditions.
  • Enhanced Cleanliness: The rough, sugar-like texture of standard powder-bed prints transforms into a smooth surface, making parts much easier to maintain and clean.
  • Professional Finish: The process imparts a sleek, professional finish that rivals traditional injection molding. This adds a level of quality crucial for presentation models and final end-user products.

Building the Future of Device Manufacturing Together

Overcoming porosity limitations allows us to build the next generation of innovative devices together. By integrating our advanced vapor smoothing technology into your production workflow, you can confidently print functional, leak-free components that perform reliably in demanding environments. We believe there is no device so complex that it cannot be brought to market effectively with the right digital manufacturing expertise.

Ready to experience the quality of true liquid-tight 3D printing? Contact our team and let us help you scale your next big idea.