By Mike Schorr, general manager, DyeMansion

Additive manufacturing (AM) often has been framed as a disruptive force – something poised to replace injection molding, machining or other long-established production methods. But that narrative misses the mark. The real strength of additive manufacturing lies not in its ability to compete, but in its potential to complement traditional manufacturing methods.

Think of AM not as a replacement wrench, but as a new tool in the manufacturing toolbox. One that offers unique capabilities that traditional methods can’t match. With its freedom of design, digital flexibility and ability to produce complex geometries without costly tooling, additive is redefining what’s possible at every stage of product development. Yet for it to be fully embraced in high-volume, regulated and quality-driven environments, the raw printed part must evolve beyond its as-printed form.

As additive manufacturing matures, it’s no longer just the playground of designers and engineers pushing out plastic prototypes. The technology quickly is staking its claim as a legitimate tool for production. But while the printers themselves have rapidly advanced, there still is a crucial gap that prevents 3D printing from fully integrating into traditional manufacturing environments – the surface finish.

Surface quality, color fastness and regulatory compliance aren’t “nice-to-haves.” They are baseline expectations for parts headed into consumer hands or industrial assemblies.

By transforming raw, unfinished parts into fully viable products – both aesthetically and functionally – additive manufacturing seamlessly integrates into traditional production workflows. From prototyping and low-volume runs to certified, end-use parts, AM is no longer an alternative to conventional processes; it’s an accelerator of innovation.

VAPORFUSE SURFACING: SMOOTHING THE WAY TO PRODUCTION
A technology that stands out working with AM as it pertains to plastics decorating, offered by DyeMansion, is VaporFuse Surfacing, a vapor-based process that goes far beyond cosmetic finishing. It chemically seals the surface of printed parts, smoothing out layer lines and porosity to create a finish that’s not just visually clean, but functionally superior.

This has major implications across the manufacturing spectrum. Take prototyping, for instance. Teams now can produce parts that match the final material and finish, reducing iteration loops and cutting down development time. There’s no longer a jarring difference between “looks-like” and “works-like.”

VaporFuse-treated parts now are directly entering production workflows. Because the process enhances airtightness, reduces friction and improves washability, it’s making 3D-printed parts suitable for use as functional inserts or even direct replacements in traditionally molded assemblies. In some cases, manufacturers are using printed and VaporFuse-sealed components in tandem with injection molding, treating AM not as a competitor, but a partner.

One example comes from the world of prosthetics. Quorum, a prosthetic device manufacturer, uses VaporFuse Surfacing to improve the interior smoothness of its prosthetic sockets (Figure 1). The sealed surface not only enhances wearer comfort but also creates a vacuum-compatible finish, critical for devices that rely on suction suspension. It’s a perfect example of how surfacing isn’t just about looks – it’s about unlocking new functional possibilities.

WHEN COLOR IS MORE THAN JUST AESTHETICS
Having a coloring system for additive manufacturing does more than add personality to printed parts. It opens the door to full-scale product viability.

For many applications, particularly in consumer goods and medical devices, color simply isn’t an aesthetic decision. It’s about consistency, UV resistance, skin compatibility and regulatory compliance. It is important in a manufacturing setting that a platform delivers on all fronts with a standardized database of color recipes and ISO-certified processing – ensuring every part comes out with the same tone, shade and safety profile, batch after batch.

As an example of this, using the DyeMansion’s DeepDye Coloring technology, Fitz Frames (Figure 2) offers custom-fit 3D-printed eyewear for kids in a palette of vibrant colors that withstand wear, sunlight and handling – while staying compliant with strict safety standards. The result is a product that doesn’t just look great out of the box but stays that way in the real world.

A coloring platform is important for all types of additive manufacturing applications, including the demands of industries such as automotive and other industrial sectors, where requirements for light and heat resistance are far more stringent. In these contexts, consistent, reproducible color isn’t just about branding – it’s essential for part validation and long-term durability.

FROM PILOT TO PRODUCTION: CASE STUDIES THAT PROVE THE POINT
The true test of any manufacturing technology is how it performs in the real world. Wilson Sporting Goods used additive manufacturing to help bring its experimental airless prototype basketball to life. The ball was 3D-printed using a complex lattice structure and finished using VaporFuse Surfacing and DeepDye Coloring for a slick, black outer skin (Figure 3). The finished result wasn’t just functional – it was playable.

In addition, Ottobock, a company that develops pediatric cranial helmets, is using additive manufacturing technology to produce lightweight, breathable and aesthetically appealing orthotic devices (Figure 4). Additive manufacturing is a perfect fit for this application because the company can take a direct scan of a patient, have it printed to the exact form and then finish the helmet using Polyshot Surfacing and DeepDye Coloring, therefore, bypassing the model maker or other manual skill to shape the helmet and taking days or even weeks off a deliverable product.

These are only a couple of real end-use parts that go through extreme capability testing measures that meet or even exceed existing standards for comparable products. There are many more applications and use cases that are clear success stories that help show where additive manufacturing can not only become a final use part, but also can enhance existing methods.

A NEW MANUFACTURING MODEL
As manufacturing moves toward more flexible, customized and sustainable models, 3D printing is becoming a powerful tool. Not because it replaces traditional methods, but because it complements them.

Injection molding remains king for mass production, but 3D printing increasingly is becoming more popular for short runs, personalized products, complex geometries and fast-track development cycles.

For plastics decorators, that shift means more than just new substrates. It means new possibilities – digitally dyed products, never-before-seen surface finishes and supply chains built for speed and flexibility.

CONCLUSION
Additive manufacturing has long promised to revolutionize how products are made. What’s been missing is the bridge between the prototype and the product – between the promise and the production line. New technologies in additive manufacturing are building this bridge, not just through hardware, but through a deep understanding of what manufacturers need: consistency, compliance and quality.

As more industries look to blend additive manufacturing into their workflows, new technologies ensure they don’t have to compromise. It’s not just about printing parts anymore – it’s about finishing them for the real world. And that’s where the future of manufacturing begins.

DyeMansion specializes in industrial post-processing solutions for 3D-printed polymer parts. Its technology covers the entire workflow from cleaning and surfacing to coloring, enabling the use of additive manufacturing for end-use applications. The company’s systems are used across various industries, including automotive, healthcare and consumer goods. For more information, visit www.dyemansion.com.