Surface quality as a decisive factor in additive manufacturing

With the increasing spread of additive manufacturing, the focus is not only on printing processes, but also on the post-processing of components. Surface quality in particular plays a key role in the functionality, mechanical performance and appearance of additively manufactured components. The British company 3D People emphasizes that post-printing processing is often just as crucial as the actual manufacturing process.

“With additive manufacturing, a part’s journey doesn’t end when the printer stops,” says Felix Manley, co-founder of 3D People. “It’s what happens afterwards that determines whether it’s an exceptional, high-performance part.” In particular, processes like polymer powder bed fusion (PBF) leave a rough surface that can be problematic in many applications. Roughness can have a negative impact on sealing properties and friction, which is particularly important in the aerospace, automotive and medical technology sectors, where tight tolerances are crucial.

In order to further establish additive manufacturing as a production process, reliable and scalable surface treatment methods are required. 3D People is investing specifically in technologies such as vapor softening, vibration polishing and precision coloring.

“We’ve invested heavily in process control for finishing technologies like vapour smoothing, vibro-polishing, and precision dyeing,” says Sasha Bruml, Co-Founder of 3D People. “Our customers don’t just need parts — they need parts that look and perform like they belong in the real world. And that means next-level surface refinement.”

In addition to functional improvement, aesthetic aspects and regulatory requirements are also important factors. In consumer goods industries, visual quality influences purchasing decisions, while precisely defined surface finishes are required in safety-critical applications such as medical technology and mechanical engineering. Without targeted post-processing, many additively manufactured components do not meet these requirements.

“People often assume AM produces a ready-to-use part straight from the printer,” adds Bruml. “The reality? Some post processing is always necessary, but raw, cleaned parts are often just the beginning. Without superior finishing, many AM applications won’t meet industry standards, and they definitely won’t meet customer expectations.”

Bruml makes it clear that post-processing is an integral part of the additive manufacturing process. Without targeted surface finishing, numerous applications cannot be realized as they either do not meet the technical specifications or customer expectations. Companies such as 3D People therefore rely on a holistic approach to the production process, in which quality is ensured not only by the printing process, but also by optimized post-processing.