SAF

Step 1

Printing

An initial layer of powder is spread across the build surface using a powder recoater blade. Piezoelectric printheads jet High Absorption Fluid (HAF) on to the powder bed in the pattern of the cross sectional slice of the 3D geometry. The powder bed is exposed to infrared (IR) energy. The areas coated with the HAF have higher emissivity, absorbing more IR energy than the surrounding powder which solidifies the cross section of the part. After each layer is exposed to the IR the build base drops down into the build chamber by the layer height dimension and another layer of powder is spread across allowing the next layer to be jetted out and exposed to IR. This is repeated until all slices of the build are completed. After the build is complete, the chamber is left to cool. This further solidifies the part, ensuring greater structural integrity. SAF uses a unidirectional print process which means every layer takes the same amount of time, this reduces uneven cooling, reducing internal stress development.

Step 2

Support Removal

Manual Removal Not required, as unfused powder provides self-support during printing. Soluble Support Removal Non-applicable. Manual Cleaning Notes: Powder removal is the primary post-processing step at this stage: Parts are typically vacuumed, air-blasted, or bead-blasted Powder is recyclable, depending on material and thermal exposure.

Step 3

Surface Finishing

Sanding / Polishing Optional; surface finish is slightly rough/matte in the as-printed state—sanding or tumbling improves aesthetics. Chemical Smoothing / Coating Vapour smoothing is compatible and enhances surface uniformity and sealing. Painting / Priming Widely used for cosmetic or branding purposes; requires surface prep for adhesion. Gloss / Matte Control Naturally matte finish; gloss achievable with coatings, smoothing, or tumbling.

Step 4

Curing

UV / Thermal Curing Non-applicable; parts are thermoplastics and fully fused during the print process. Annealing / Stress Relief Non-applicable.

Step 5

Assembly and Functional Finishing

Gluing or Bonding Compatible with common thermoplastic adhesives (e.g., cyanoacrylates, epoxy.) Drilling / Tapping / CNC Frequently performed to add holes, threads, or mating surfaces—SAF parts are machinable. Inserts / Fasteners Heat-set inserts, press-fit components, or threaded inserts are commonly added for mechanical assemblies.

Step 6

Special Treatments

Infiltration / Sealing Not required, though vapor smoothing can reduce porosity and improve sealing. Functional Coatings Anti-static, UV-protective, or colour coatings may be added for specific environments. Post-print Functionalisation SAF parts are often dyed, assembled, or integrated into larger systems.