3D fusion manufacturing

3D Fusion is a novel additive manufacturing method used to improve the isotropic strength, quality, and structural consistency of as-built 3D printed parts.

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So why alter, or process 3D parts?

As-built 3D printed parts typically suffer from 3 common drawbacks...

  • Lack of (isotropic) strength
  • Pourosity, and part inconsistencies
  • Issues with scaling production economically
3D parts suffer from lack of strength

3D Fusion addresses each of these and more!

Before using 3D Fusion

before 3D fusion
before 3D fusion

After using 3D Fusion

after 3D fusion
after 3D fusion

3D fusion post-printing processes

3D Fusion consists of 3 additive processes which are applied to parts after they have been 3D printed:

Freezing (frēziNG)

To hold at a fixed level or in a fixed state for a period of time.

  • Generally speaking, Freezing increases the quality, consistency, and usability of 3D printed parts for home, industrial and commercial use, by fusing the plastic connections present in 3D printed parts, wherever they are. This bolsters and strengthens the as-built part, which likely harbors inconsistencies and flaws in the bonded plastic ribbons laid down during the 3D printing process.
  • Not only is the part made strong across all axes (isotropic strength), but Freezing actually gives the part added stiffness when placed under low stress loads, and added flexibility under high stress loads. These are highly desirable characteristics.
  • Freezing fills small gaps and fissures in the outer surface of the part making it smoother, more durable, and more attractive, without noticeably impacting dimensional accuracy. Freezing increases air and watertight qualities. Various other qualities may be added to parts in the Freezing process by simply changing the chemical formulation of the materials used ie. add UV Blocking, fire retardant, food safe, etc.

Casing (kāsiNG)

A cover or shell that protects or encloses something.

  • The Casing process seals the outer surface of as-built 3D printed parts, and ensures air & watertight qualities. It does so by addressing flaws in the outer walls, ceiling, and floor surfaces which are left behind by the 3D printing process. It’s these flaws which are primarily responsible for porosity, and a lack of consistent strength in as-built parts.
  • Casing strengthens the outer shell and improves adhesion between surface layers wherever flaws may exist.
  • The Casing process measurably verifies air & watertight finish.

Loading (lōdiNG)

The application of an extra amount of something to balance some other factor.

  • Loading of as-built 3D printed parts boosts the isotropic strength of those parts substantially. *The level of strength added is heavily dependent on the geometry and materials used in Loading the parts. Nevertheless, the results are nothing short of extraordinary!
  • Mass, density, stiffness, and strength of (sparse-filled) 3D printed parts can be bolstered, manipulated, or customized to whatever degree is afforded by the part’s as-built geometry
  • Loaded parts are air & watertight.
3D fusion elevates parts

A fully functioning 3D printed part (brake handle) using our 3D Fusion technology.

3D fusion elevates printed parts

3D Fusion bolsters the as-built structure of 3D printed parts, elevating them to a new level physically, and chemically. 3D printed parts treated with these processes are enhanced with benefits and qualities not present in the original prints, as outlined in the descriptions above.

primary production benefits of 3D fusion


Combining 3D Fusion with 3D Printing elevates part consistency to Certifiable Standards.

enhanced strength

3D Fusion enhances part strength across all axis and fuses all as-built structures into one.

air & watertight

3D Fusion creates airtight and watertight qualities among the 3D printed parts (verified in process).

our 3D fusion technology at a glance

elevating 3d printed parts

It should be clear that the immediate benefits which flow from 3D Fusion are poised to elevate 3D printed parts (particularly FDM parts) to a new level of success in real world applications, well beyond that which the 3D printer platforms themselves are able to achieve (economically) on their own.

expanding commercial use of 3d printing

3D Fusion is complementary to the interests of both 3D print Users (Maker’s), and 3D Printer Manufacturer’s, as it will complement the hardware capabilities and help to define a path to expanded commercial use of 3D printed parts more generally.

sustainable manufacturing, unlimited possibilities

Finally, manufacturing itself will ultimately benefit from the new fabrication methodology prescribed here, because it opens the door to new production potential which is virtually unlimited in use, highly accessible, broadly distributed, and ultimately sustainable.

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Digital Manufacturing and fully scaled Production using 3D printing and AM is finally here!

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customer reviews

"My company and I have used 3D prints from here many times at this point. Always impressed by the professionalism and willingness to take the extra step. Great source of 3D printing experience if you're not familiar with the intricacies of designing using additive manufacturing."


"I needed to develop a prosthetic foot that could be subjected to loads of 225 lbf for >500k cycles. I tried to develop an exclusively 3D printed solution but the the FDM & SLA solutions regularly failed 50k cycles. The hybrid print & fill strategy Rob employs substantially increased the durability of the prosthetic. To underscore the durability of the final design of the prosthetics, some of the metallic components (bolts & spring steel) had to be replaced while the PLA/polyurethane components are still going strong (>1M cycles)."


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