Vapour Smoothing
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Vapour Smoothing for 3D Printed Parts
Vapour smoothing, also known as vapour polishing, is a post-processing technique that enhances the surface quality and performance of our powder-based 3D printed parts, such as PA (Polyamide) and TPU (Thermoplastic Polyurethane) 3D printed components, made using our SLS and MJF technologies.
Our new in-house post-processing service uses a controlled chemical vapour environment to physically smooth the part’s surface, reducing porosity and eliminating the typical powder-based course texture. The result is a sealed, uniform finish that closely resembles injection-moulded plastics, improving both appearance and functionality.
Unlike abrasive or mechanical finishing, such as sanding or tumbling, vapour smoothing penetrates the surface layer, creating a more robust exterior and more predictable strength characteristics. This makes vapour smoothing ideal for prototypes and production-grade parts where durability, watertightness, and refined aesthetics are essential, without introducing foreign materials or coatings. The parts remain composed entirely of the original printed material.
MJF 3D Printed part before and after vapour smoothing.
SLS 3D Printed part before and after vapour smoothing.
Why Vapour Smoothing Matters
For engineers and designers, surface quality is more than cosmetic, it improves performance, hygiene, and reliability. Vapour smoothing transforms as-printed, porous Nylon PA surfaces into a uniform, smooth, sealed layer that better resists contamination and is easier to clean. This is critical for components exposed to fluids, handling, or environments requiring strict hygiene standards.
Beyond aesthetics, the process improves mechanical properties. The strengthened outer layer enhances wear resistance and dimensional stability, ensuring parts maintain their integrity under repeated use or load. For applications where 3D printed components need to mimic injection-moulded behaviour, vapour smoothing bridges the gap, delivering parts that look and perform like moulded plastics.
Applications and Benefits
Vapour smoothing is suitable for most PA parts across a wide range of industries and use cases:
- Consumer products requiring a refined, uniform finish. Glossy or fine matte surfaces can be achieved by strategically combining our advanced post-processing techniques.
- Functional prototypes that need improved toughness and reliability.
- Hygienic & Skin-friendly allowing for a greater range of applications including wearables, medical devices and consumer products.
- Processed using chemistry certified under EU 10/2011, supporting smooth, cleanable surfaces where hygiene is a key consideration.
- Medical and assistive devices where clean smooth surfaces maintain hygiene and comfort.
- Mechanical housings and enclosures, and living hinges exposed to repeated handling or wear.
- Components for airflow or fluid movement, where smooth sealed surfaces improve flow characteristics.
Whether you need watertight parts, enhanced durability, or a professional-grade finish, our vapour smoothing service delivers parts that excel in appearance and performance.
MJF 3D Printed part before and after vapour smoothing.
Our Capabilities
Formero’s vapour smoothing system features a chamber that measures 700x600x500 mm, enabling finishing for larger parts.
Formero’s vapour smoothing service uses a biodegradable solvent, offering an environmentally responsible solution without compromising quality or consistency.
By combining material expertise with advanced finishing technology, Formero helps customers validate designs more accurately and produce parts that meet demanding functional and aesthetic requirements.
Ready to upgrade your 3D printed parts? Request a quote today and discover how vapour smoothing can enhance your project.
Frequently Asked Questions (FAQ)
Vapour smoothing is a chemical post-processing method that smooths and seals (Nylon PA & TPU) 3D printed parts, reducing porosity and improving surface finish.
Formero offers vapour smoothing for PA parts produced via MJF or SLS. While the process can apply to TPU, we do not currently print TPU parts in-house.
It creates a tougher outer layer, enhances wear resistance, and delivers more predictable strength characteristics, making parts behave closer to injection-moulded plastics.
Our technology is not compatible with FDM materials. The chemistry and equipment are designed specifically for PA and TPU. FDM materials require a separate finishing method that uses different solvents and principles.
Yes, fine text, sharp corners and crisp edges may soften slightly. We can work with you and your files to achieve the best possible outcome.
Yes. The sealed surface reduces porosity, making parts more resistant to fluid ingress and easier to clean.
Our system’s chamber is 700×600×500 mm, this allows for vapour smoothing large parts, or higher quantities at once.
Formero uses a biodegradable solvent, providing an eco-conscious solution without compromising quality.
Yes, we can provide vapour smoothing for externally printed PA or TPU parts. However, our preference is to work with components produced in-house, as this allows us to guarantee the highest quality results. When parts are sourced from other manufacturers, we cannot verify the material quality or print integrity, which may affect the outcome. For this reason, we assess these requests on a case-by-case basis.
If you have parts you’d like us to review, please contact our team to discuss suitability and next steps.
We like to use “vapour smoothing” because it better reflects the main benefits of the process: creating a smooth, sealed surface that improves both aesthetics and functionality. While “polishing” suggests a cosmetic finish, vapour smoothing also enhances mechanical performance and watertightness. In addition, because of the advanced technology we use, we are able to process parts to varying intensities, giving us greater control over the results both physically and aesthetically.
