Vapour Smoothing: Closing the Gap Between 3D Printing and Moulded Parts
February 12, 2026
We’re pleased to introduce our new Vapour Smoothing Service, designed to enhance the surface quality and performance of powder-based 3D printed parts. By bringing this capability in-house, we now offer Vapour Smoothing locally for PA components produced using MJF and SLS technologies.
While additive manufacturing continues to evolve, surface texture and porosity remain common differences between 3D printed and injection-moulded parts. Vapour Smoothing addresses these limitations by refining and sealing the outer surface of the component, helping printed parts look and behave more like moulded plastics.
What Is Vapour Smoothing?
Vapour Smoothing is a controlled post-processing method that acts on the outer surface layer of a 3D printed part. During the process, a carefully managed vapour environment softens the exterior of the polymer. The material reflows at a microscopic level before re-solidifying into a smoother, more uniform surface.
Unlike coatings or paints, Vapour Smoothing does not add material to the part. Instead, it consolidates the existing surface, reducing porosity and removing the natural powder texture associated with powder-based additive manufacturing.
The result is a sealed exterior that improves both appearance and functional performance.
Vapour Smoothing MJF & SLS Parts
Our Vapour Smoothing Service is specifically suited to PA (Polyamide) parts produced using Multi Jet Fusion (MJF) and Selective Laser Sintering (SLS).
As-printed MJF and SLS components offer strong mechanical properties, but their surface texture can limit use in certain environments. Vapour Smoothing MJF parts reduces surface roughness and seals micro-porosity, making them easier to clean and more resistant to moisture.
Similarly, Vapour Smoothing SLS parts improves surface consistency and supports more predictable behaviour under repeated handling or load. For parts intended for functional testing or end-use applications, this added reliability can be significant.
In both cases, the process helps bridge the gap between additive manufacturing and traditional moulding, particularly for low-volume production runs where tooling is not viable.
How Vapour Smoothing Improves Performance
The benefits of Vapour Smoothing extend beyond aesthetics.
By consolidating the outer surface layer, the process creates a tougher exterior skin. This can improve resistance to wear, reduce friction in sliding applications and support more consistent mechanical behaviour during repeated use.
Sealing surface porosity also supports improved cleanability and better resistance to water ingress. For applications involving regular handling, exposure to fluids or hygiene requirements, this can be a meaningful improvement over untreated parts.
For engineering teams evaluating additive manufacturing for end-use components, a Vapour Smoothing Service can remove one of the key barriers to adoption: surface performance.
When to Consider Vapour Smoothing
Vapour Smoothing is commonly applied when:
- Parts require a refined, moulded-like finish
- Cleanability and reduced porosity are important
- Components are exposed to wear or repeated handling
- Functional prototypes need to better represent final production intent
- Low-volume production parts are being used in real-world environments
- It is particularly effective for PA12 and similar polyamide materials where performance and surface behaviour must align.
- Applications requiring coloured SLS parts with a improved dye finish
An Integrated Vapour Smoothing Service
By offering Vapour Smoothing as an integrated service alongside MJF and SLS production, we can ensure consistent quality and streamlined workflows. Parts can be evaluated during the quoting stage to determine whether Vapour Smoothing is appropriate based on geometry, function and performance requirements.
As 3D Printing continues to move from prototyping to production, surface refinement and durability become increasingly important. Our new Vapour Smoothing Service is designed to support that transition, helping customers achieve parts that not only look closer to moulded plastics, but perform closer to them as well.
For further information on Vapour Smoothing MJF and Vapour Smoothing SLS parts, get in touch with our team today.
Author
Craig Alexander
Craig leads the marketing and brand strategy at Formero, where he communicates complex manufacturing capabilities in a clear and practical way. He works across Formero’s advanced manufacturing services to create content that informs, educates, and supports engineers, designers, and procurement teams in making confident production decisions.
