DyeMansion Surface Technologies at Midlands 3D

As the performance and applications of 3D printing continue to expand, the demand for high-quality surface finishes on polymer parts has grown significantly, particularly in industries like automotive, orthotics, consumer goods, and industrial manufacturing. At Midlands 3D, we offer advanced post-processing and 3D print part finishing services, including state-of-the-art surfacing technologies from DyeMansion. These technologies allow us to transform raw powder bed fusion (PBF) parts, either SLS or HP MJF, into market-ready components with excellent aesthetic and functional qualities. Based on information primarily supplied by DyeMansion, this knowledgebase article provides a summary of the capabilities and benefits of DyeMansion’s PolyShot Surfacing (PSS) and VaporFuse Surfacing (VFS) technologies, both of which are available through our finishing services. Download the full whitepaper here: DyeMansion Surfacing Whitepaper (PDF)

Why Finishing Matters for 3D Printed Plastics

Powder Bed Fusion processes create parts with rough surfaces and visible layer lines. These untreated surfaces can trap dirt, reduce part performance, and limit usability in clean or aesthetic-sensitive environments. Effective surface treatment improves:

• Scratch resistance
• Hygiene and washability
• Colour consistency
• Assembly (e.g. gluing or painting)

PolyShot Surfacing (PSS) – Mechanical Surface Refinement

Best for: Rigid polymers like PA11 and PA12 Finish: Matt-glossy, scratch-resistant, pleasant haptics

How It Works

PolyShot Surfacing uses accelerated bead blasting (not tumbling) to plastically deform and homogenise the surface of the part—without removing material or altering geometry. This is ideal for production parts where dimensional integrity is critical.

Key Benefits

• Creates a uniform matt-gloss finish
• Increases scratch resistance and dirt repellence
• Improves colour absorption with our DeepDye Colouring service

Sample Applications

• Automotive interior trims
• Orthotic and prosthetic components
• Consumer eyewear and lifestyle goods

Limitations

• Less effective on flexible TPU materials
• Limited reach into internal channels or thin, delicate structures

VaporFuse Surfacing (VFS) – Chemical Vapour Smoothing

Best for: Flexible or complex parts (including TPU, PA11, PA12) Finish: Glossy, sealed, injection moulding-like

How It Works

This contactless vapour-based chemical process condenses solvent onto the surface of the part, softening the top layer and allowing the polymer chains to reorient. After drying, the surface solidifies into a smooth, sealed skin.

Key Benefits

• Ultra-smooth, glossy finish
• Sealed and washable surface (Ra < 2 µm)
• Compliant with EU food contact regulations (EU 10/2011)
• Suitable for fluid-carrying, wearable, or cleanroom applications

Sample Applications

• Sealed housings
• Footwear midsoles
• Food-safe packaging
• Medical device components

Limitations

• VFS affects entire surface—so contact points (e.g., where parts rest on racks) may show marks
• Not suitable for parts with moving joints post-processing
• Requires careful CAD preparation to allow suspension or support

Measured Improvements

Both PSS and VFS dramatically reduce roughness and improve haptics, while VFS offers superior gloss and water resistance.

Which Process Should You Choose?

Need guidance on the best finish for your application? Contact us to discuss your part and performance requirements.

Learn More

• View all finishing services
• Explore additional services including 3D scanning, inspection and assembly
• Partner with Midlands 3D as your strategic additive manufacturing partner

Download the DyeMansion Whitepaper

Download the full DyeMansion Surfacing Whitepaper (PDF)