If you think the topic of 3D printing seems confusing or overwhelming, you’re not alone. There’s a lot to consider. But the more you learn the clearer the picture will become. A good place to start is becoming familiar with the different additive manufacturing (AM) technologies – the 3D printing methods – that exist in the marketplace. To help you toward that goal, this post takes a closer look at one of those technologies – powder bed fusion – so you can better understand how it’s used, where it fits, and when to consider it.
Powder bed fusion (PBF) is a sophisticated AM process that builds parts layer by layer from a bed of finely powdered material. The method uses an energy source—typically a laser, an electron beam (in the case of metals), or another form of heat source — to selectively fuse regions of the 3D printing powder into solid structures based on a digital design. Unused powder surrounding each part serves as a natural support, enabling the creation of complex geometries without the need for additional scaffolding (except for metal).
The powder bed fusion process is divided into several broad categories differentiated by the method of heat used:
Each approach shares the core principle of building parts from a bed of powder, but the fusion mechanism and suitable materials vary, affecting their ideal use cases. Although metal accounts for a large percentage of PBF market share, this blog post will focus specifically on polymer PBF 3D printing.
The powder bed fusion process can be broken down into a series of precise steps. First, a thin layer of pre-heated powder is spread across the build platform. Then, a source of thermal energy selectively fuses the powder according to the cross-section of the digital model. Once a layer is fused, the build platform lowers slightly, and a new layer of pre-heated powder is added and fused.
A simplified schematic of the powder bed fusion process.
This layer-by-layer approach continues until the parts are completely formed. Once the build is complete, the parts cool down in the powder bed. After cooling, any remaining loose powder is removed, often to be reused in future prints. Additional post-processing steps like bead blasting, dyeing, or vapor smoothing may be necessary depending on design requirements.
One aspect affecting powder bed fusion materials is their eventual degradation. Exposure to the printing process deteriorates the material’s thermal properties. As a result, the PBF process requires used powder to be refreshed with a mix of new powder, the amount depending on the capabilities of the specific powder bed fusion technology and printer being used. The unusable powder becomes a waste by-product of the process.
Breaking the parts out of the powder “cake.”
Like other forms of 3D printing, the PBF process offers near-unlimited design freedom as well as time and cost efficiencies compared to traditional methods of manufacturing. However, there are a few characteristics that set it apart from other additive manufacturing methods:
A CAD model of a part and its representation in a nested build.
Another advantage of powder bed 3D printing which is sometimes overlooked is its ability to produce almost isotropic parts – parts with consistent mechanical properties in all directions. This is favorable for critical load-bearing functional components. In contrast, some other AM processes create anisotropic parts where characteristics, such as strength, differ across build axes. This creates variability in mechanical properties across the part’s geometry, such as being stronger in one direction and not as strong in another.
Unlike many 3D printing processes, polymer PBF parts are made from thermoplastics which are intrinsically recyclable, making the processes more sustainable which is especially important as 3D printing expands into volume production.
Because of the benefits powder bed printing offers, it has applications in virtually any industry involved in some form of manufacturing.
A automotive component 3D printed using PBF technology.
Eyeglass frames printed with PBF technology.
espite its strengths, 3D printing with powder bed fusion does come with considerations that warrant careful evaluation.
Cost of equipment is one of the highest among additive technologies.
Material options are expanding but other polymer AM technologies offer more options.
Depending on your applications, other forms of AM like FDM®, PolyJet™, or P3™ DLP technologies may be a better fit since they don’t have the same facility and environmental considerations. These technologies also offer a wider range of materials.
A post-process tumbling operation used to smooth the surface finish of 3D printed eyeglass frames.
Although PBF additive technology has been around for about 40 years, it hasn’t stood still, and new developments continue to push its capabilities.
Together, these innovations are making powder bed fusion more accessible, efficient, and powerful.
Stratasys brings its AM expertise to powder based fusion through its SAF® Selective Absorption Fusion® technology, currently utilized on the H350™ powder bed 3D printer. SAF technology uses an infrared-absorbing agent deposited by industrial print heads and infrared heat lamps to selectively fuse polymer powders.
The SAF H350 powder bed fusion 3D printer.
Designed to address shortcomings with existing polymer PBF options, the innovation behind the H350 printer and SAF technology gives manufacturers several key benefits beyond current marketplace PBF options.
GO Orthotics wanted a more efficient and cost-effective solution for custom, patient-specific orthotics. They found it in the H350 printer with SAF technology.
One of the design objectives for SAF technology was to enable the use of additive manufacturing in production environments, particularly for increased-volume end-use parts, while minimizing operating costs and streamlining workflows. But more importantly, SAF technology was developed to improve current polymer PBF technology.
Some of the highlights where the H350 3D printer and SAF technology address pain points with current powder bed 3D printing include:
The H350 printer uses a patented unidirectional print mode vs. a bi-directional method used on competing systems. Additionally, the H350 printer uses a high-resolution thermal camera – 100 times more accurate than other systems. This combination produces consistent thermal control across the print bed, resulting in accurate parts throughout the build and high yield.
The H350 printer achieves nesting densities up to 43% with virtually zero material waste. Other polymer powder bed fusion systems currently available can achieve about 10%-12% densities. The H350 printer also uses fewer consumables. These factors combine to lower operating costs and increase throughput, lowering cost-per-part.
GrabCAD Print Pro™ software can generate automatic build reports with job traceability at no additional cost, something that’s not possible with competing systems. Print settings are customizable, too, letting you adjust as needed to adapt to different applications.
The H350 printer has the lowest energy cost per kilogram of printed parts in its class, based on back-to-back testing against the competition. It also has a smaller footprint, allowing two printers to be installed in the same space as one competing system. Smaller spaces equate to reduced needs for temperature and humidity control, contributing to the technology’s overall lower carbon footprint.
The PowderEase™ T1 accessory streamlines powder handling with automated breakout, part retrieval, and powder dosing. This significantly reduces the labor required to process the parts after printing, letting customers focus on other tasks. It also improves workplace safety and efficiency by reducing manual powder handling, limiting dust exposure, and reclaiming unused powder more efficiently.
The PowderEase T1 automated powder dosing and part retrieval system used with the H350 printer.
In addition to these benefits, one standout sustainability innovation with SAF technology is SAF ReLife PA12. This capability allows the used PA12 waste powder from SAF and other powder-based technologies to be used in the H350 3D printer. This eco-conscious approach can reduce carbon emissions by up to 90%, effectively turning waste into value.
SAF PBF technology currently makes use of three types of powder bed fusion polymers:
This 3D printed automotive speaker cover is made with polypropylene on the H350 3D printer using SAF technology.
As a reference, PBF processes outside of SAF technology can use those same materials in addition to others that may include:
If you noticed that powder bed printing offers fewer materials than other additive technologies, your perception is accurate. The main reason has to do with the challenges certain polymers pose in turning them into a powdered form. Not all plastics have the balanced thermal properties required for adaptability to powderization. That said, the nylon-based materials used with polymer PBF are able to cover a lot of applications. Additionally, development of nylon-based carbon- or glass-filled composite materials continues, offering more options.
A view of the H350 printer building a part layer in the powder bed fusion process.
While Stratasys offers SAF technology, other powder bed fusion processes also play significant roles in the additive landscape.
Each technology has strengths, but the Stratasys SAF platform stands out for its efficiency, repeatability, and favorable economics.
In PPBF, particles are pre-heated to a temperature just below their melt point, extra heat is then applied selectively to melt particles in areas that will form the manufactured parts; these particles fuse together and later solidify to form the manufactured parts.
Discoloration often results from thermal degradation of the powder, especially when reused powder is exposed to prolonged heat during the printing process. This can affect both aesthetics and mechanical properties.
Yes, materials like Rilsan® PA11 are bio-based and biocompatible, making them suitable for medical applications such as orthotics and prosthetics. Medical-grade PA12 variants are also certified for skin contact and limited internal use.
A11 is more ductile, better for impact resistance, and has greater elongation at break. PA12, on the other hand, is stiffer, has excellent dimensional stability, and offers tighter tolerances.
It depends on the specific technology used. Each cycle exposes powder to heat and oxygen, degrading its chemical structure and printability. Most systems recommend a refresh rate—adding 20–50% virgin powder—to maintain quality in reused batches. Thanks to SAF technology’s gentle thermal control, however, it can utilize all powder without generating any waste stream (beyond the powder that gets lost in the cleaning process).
Common indicators include poor layer spreading, inconsistent part strength, increased brittleness, and visible surface defects. Repeated use also leads to increased particle size and oxidation, reducing fusion performance.
No. The surrounding unfused powder supports overhangs and complex features, enabling the creation of intricate geometries without needing physical support structures. This simplifies design and post-processing.
Yes, polypropylene, which has low moisture absorption and good chemical resistance, can be used to produce parts that are watertight and airtight.
As a pioneer in additive manufacturing, Stratasys redefined the powder bed fusion landscape. SAF technology and the H350 3D printer were designed to take the polymer PBF process to a new level of performance that gives manufacturers tangible advantages relative to the status quo. Cost efficiencies, a streamlined workflow, and sustainability features come together to make SAF technology and the H350 printer an optimal choice for powder bed fusion 3D printing.
To learn more, visit the SAF Technology web page.
If you’re looking for a deeper dive into how to choose a 3D printing technology, check out our Buyer’s Guide. It offers a comprehensive look at each Stratasys technology, where they fit best, and considerations you should think about.
