POWERFUSE S: Fusing the gap between 3D-printing and Additive Manufacturing – the revolutionary manufacturing method for better products and a more sustainable future

Today, plastic 3D-printing cannot fully exploit its potential. The surface qualities do not meet the requirements of the products. Rough surfaces, obtained on as-printed parts, are matt, susceptible to dirt, a breeding ground for germs and do not exhibit an appealing appearance. This is where the Powerfuse S comes in. It enables a scalable surface smoothing of 3Dprinted polymer parts by a stable, reproducible and environmentally friendly physio-chemical process, the so-called VaporFuse Surfacing (VFS). Apart from optical advantages, the VFS treated parts offer smooth, water-repellent and glossy surfaces. The parts have wipeable surfaces for food and medical applications, increased mechanical properties and scratch resistance and assure water- and airtightness for carrying fluids or gases. VFS can substitute the extensive preparation for subsequent spray coating and delivers powder residue-free parts for clean room applications. VFS challenges traditional injection molding for the first time and enables 3D-printing to finally become Additive Manufacturing. Within this project, the Powerfuse S is to be further developed into a large-scale, industry 4.0-ready, sustainable system. The smoothing processes are optimized and developed for other industry-relevant polymers. Parallel to the technical side, all legal, sales and operational foundations are being laid to get this pioneering product to market. Automated post-processing of AM parts is inevitable to fully exploit all advantages of AM like mass customization of complex products with reduced costs and production times as well as a decrease of waste and scrap. It opens unprecedented possibilities for the production of tomorrow and has the potential to disrupt whole industries. Especially the enablement of on-site production and reducing complexity of global supply chains as well as enabling weight reduction in the aerospace industry through complex product design is a key enabler in saving energy and GHG emissions.