FABULOUS and AMT validate workflow for 3D printing food-safe parts

In the food industry, regulatory compliance is essential and any lapses can have real consequences when it comes to food-borne illnesses. A central part of this compliance is related to materials. That is, all equipment used in food processing and packaging must not only be kept sanitary, but also be made from food-safe materials, like stainless steels, glass, and specific plastic grades.

For years, these strict material standards limited the use of 3D printing for industrial food-contact applications, however recent advancements in thermoplastic materials have unlocked opportunities in this area. A number of these innovations have come from FABULOUS, a France-based company that specializes in the development of polymer powders for SLS 3D printing, including food-safe materials identifiable by their bright blue color.

Recently, FABULOUS achieved a milestone in collaboration with post-processing solutions company AMT. Together, the companies validated food contact compliance for 3D printed parts made using the former’s DETECT PA11 powder and finished using AMT’s PostPro Pure vapor smoothing technology. The validation process was led by an accredited third-party laboratory in accordance with U.S. FDA 21 CFR §177.1500 (for nylon resins) and Regulation (EU) No 10/2011 for materials intended for food contact.

FABULOUS’ DETECT PA11 is a bio-based nylon composite that is not only optically detectable (with its bright blue color), but can also be detected using magnetic and X-ray tests thanks to the inclusion of special additives. The powder has been engineered for food and pharmaceutical applications, however even printed parts made from DETECT PA11 can feature small pores that come with food safety risks. This is why FABULOUS teamed up with UK-based AMT. The latter’s vapor smoothing technology can take porous 3D prints and turn them into sealed, durable components that are food contact safe and easy to clean.

“Post-processing plays a critical role in achieving functional and compliant 3D printed parts,” explained Dr. Konstantin Rybalchenko, Chief Scientist at AMT. “Together with FABULOUS, we have validated a complete workflow that enables manufacturers to produce parts that meet regulatory standards while maintaining the benefits of additive manufacturing.”

In the workflow validation process, a number of tests were conducted to evaluate the 3D printed and vapor smoothed parts. According to the partners, all test results fell well within regulatory limits. “This collaboration marks a turning point for the industrialization of 3D printing in highly regulated sectors,” added Olivier Coulet, CTO at Fabulous. “Our customers now have access to a certified, reliable solution, free from technical or regulatory barriers so they can focus on innovation.”

FABULOUS’ food-safe printing materials, including DETECT PA11 and BLUECARE PA11 first launched in Europe and found applications in the production of food conveyor belts, food scrapers, robot clamps for packaging, spare parts, and more. In 2024, they became available in the United States after receiving “the highest food contact certifications from the FDA CFR21 positive list”. In the market of food-grade 3D printing materials, French 3D printing service Sculpteo last year introduced PA12 Blue food grade, which can also benefit from chemical smoothing to seal the surface of printed parts for food industry applications.