Green transformation in 3D printing: advances in vapor smoothing through sustainable solvents

The 3D printing industry is currently undergoing a significant shift towards more sustainable and environmentally friendly processes. New standards are being set, particularly in the field of vapor smoothing, to reduce the use of harmful chemicals while achieving high surface quality. Leading service providers such as Forecast 3D, RapidCenter and FKM rely on the innovative Powerfuse S technology from DyeMansion. This solution enables 3D-printed plastic parts to be smoothed efficiently using green solvents, thereby establishing more environmentally friendly processes.

Traditional processes for smoothing 3D printed parts often used open solvent baths, which posed risks to both operators and the environment. The use of fluorinated solvents such as HFIP fell under the category of PFAS, also known as “Forever Chemicals”, which are known for their longevity and environmental impact. To address this issue, DyeMansion developed the Powerfuse S in 2019, based on feedback from industry partners and users. This technology relies on a closed-loop system that recycles the solvent used, reducing environmental impact and operating costs.

The use of green solvents has not only proven to be safer for personnel, but also reduces the need for extensive protective measures, such as separate production areas or special extraction systems. This development promotes efficiency and reduces operating costs in the long term.

Floris Stam, Managing Director at RapidCenter says: “At RapidCenter, we prioritize sustainable and scalable solutions that align with our commitment to innovation and environmental responsibility. We chose DyeMansion’s Powerfuse because it combines industrial-grade performance with a green vapor smoothing process, ensuring both quality and eco-friendliness in our 3D printing operations.”

In addition, the use of these solvents offers regulatory compliance benefits, such as food safety under FDA 21 CFR or EU Regulation 10/2011, and companies like Forecast 3D have already integrated the Powerfuse S into their production processes.

“Forecast 3D is proud to add the VaporFuse system from DyeMansion to our robust suite of offerings to further enhance our vapor smoothing solution. The benefits of a green solvent — coupled with automation — allow for an environmentally conscious offering at scale as part of our greater manufacturing solutions portfolio”, says Ken Burns, Vice President Commercial at GKN Additive.

The broad acceptance of this technology shows that the industry recognizes the shift towards greener processes as necessary and beneficial. Switching to sustainable processes such as the use of Powerfuse S helps to reduce PFAS while improving the efficiency of 3D printing production.

Phil Arnold, CEO of Endeavor 3D says, “It’s unsurprising that others are joining us and embracing vapor smoothing technology. Being an early adopter of best-in-class innovation is what Endeavor 3D stands for and in the past three years, our customers have benefited greatly by this investment. We prioritize the future of engineering and are committed to leaner and greener manufacturing.”