Selective Absorption Fusion (SAF)

High-volume powder bed fusion for durable, end-use plastic parts, engineered for repeatability and speed.

The SAF Process

Selective Absorption Fusion (SAF) is an industrial powder bed fusion process built for high-volume, repeatable production of end-use plastic parts. Instead of a laser, SAF uses an inkjet-style print head to deposit an infrared-absorbing fluid onto a bed of polymer powder. Infrared lamps then pass over the bed, and the areas coated in fluid heat up faster than the powder around them, fusing only the material that makes up that layer's cross-section while everything else stays loose.

Because the fusing energy is delivered uniformly across the entire bed rather than traced point-by-point, SAF holds consistent thermal conditions throughout the build. That even heat distribution is what gives SAF parts their characteristically uniform mechanical properties and smooth, consistent surface finish — with less variation between parts printed in the same job, and between different jobs over time, than many other powder-based processes.

The Appeal of Selective Absorption Fusion Process

Uniform thermal profile across the full build, consistent mechanical properties in all directions, smooth matte surface finish, high nesting density for cost-efficient production, no dedicated supports required, recyclable powder.

Because parts are nested and self-supported in loose powder during the build, SAF is well suited to complex geometries, thin walls, and interlocking or moving assemblies, with no need for dedicated support structures.

One-pass print-and-fuse per layer with even, whole-bed heating, giving repeatable part quality from the first unit to the last, run after run.

Parts are densely nested within the build chamber to maximize the number of parts per job, then left to cool inside the powder cake before being unpacked, depowdered, and finished.

Selective Absorption Fusion Process Materials & Applications

Nylon PA11

Selective Absorption Fusion (SAF) Nylon PA11 is a high-performance, bio-based nylon powder ideal for production-grade 3D printed parts. Derived from renewable castor oil, SAF PA11 delivers outstanding ductility, high impact resistance, and excellent chemical resistance. This material is optimized for demanding applications in automotive, industrial, medical, and consumer sectors, making it a sustainable choice for strong, flexible end-use components.

Explore the design guidelines for Nylon PA11

Polypropylene (PP)

Selective Absorption Fusion (SAF) Polypropylene (PP) is an industrial-grade, powder-bed fusion polypropylene engineered for high accuracy and cost-effective production. SAF PP enables durable, lightweight parts with outstanding chemical resistance, flexibility, and watertightness. It’s perfect for air- and fluid-handling applications, living hinges, consumer goods, and any use case demanding strong, ductile, and chemically resistant components.

Explore the design guidelines for Polypropylene (PP)

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