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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.

Field of science

  • /natural sciences/chemical sciences/polymer science
  • /engineering and technology/mechanical engineering/manufacturing engineering/additive manufacturing

Call for proposal

See other projects for this call

Funding Scheme

SME-2b - SME Instrument (grant only and blended finance)


Robert Koch Strasse 1
82152 Planegg-munich
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
EU contribution
€ 1 498 404