The Netfil Process

Modern resin-based composites continue to face a fundamental limitation: residual porosity across multiple length scales. While conventional degassing methods are effective at removing visible and entrapped air, they primarily operate at the macroscopic level, leaving behind micro- and nano-scale porosity that remains inaccessible to traditional vacuum or centrifugal techniques.

NETFIL is our proprietary degassing process. Unlike conventional degassing approaches which are targeted towards visible bubbles and microporosity, our process achieves a submicroscopic nano pore-free state or condition. By eliminating nano porosity, our Netfil process facilitates the manufacture of a more homogeneous and damage tolerant composite structure.

The reduction of nano-porosity has a direct influence on the internal energy balance of an isotropic composite. Micro or nano scaled pores in general have no order and they act as localized energy reservoirs and stress concentrators; their removal alters the energy landscape of the isotropic composite material or resin, resulting in a more stable and damage tolerant composite microstructure. 

This shift in internal energy distribution leads to significant improvements in material performance and printability unlike conventional degassed resins.

As a result, NETFIL-processed composites exhibit enhanced fracture toughness and improved damage tolerance, particularly under high strain or rapid loading conditions.

 By addressing porosity at scales beyond the reach of conventional degassing methods, NETFIL establishes a new standard in resin processing and unlocks mechanical performance that traditional approaches cannot achieve.

The most important and immediate benefit of NETFIL processing is a clear improvement in elastic modulus. This increase in modulus arises from the effective elimination of nano-scale porosity, which raises the realized density of the resin toward its theoretical density. As internal voids are removed, constitutive relationship within the composite  becomes more efficient and the material behaves closer to its true elastic potential. By improving density at the sub-microscopic level, NETFIL enables the resin to approach its theoretical modulus without relying on additional fillers or reinforcements.

Surface profile analysis of NETFIL-processed resin composites shows a clear improvement in surface quality, with a significant reduction in surface roughness. This enhancement is driven by a reduction in nano-scale porosity within the material, resulting in a more compact and uniform surface structure. By minimizing nano-pores, NETFIL processing creates smoother surfaces with improved consistency, supporting better mechanical performance and long-term durability.

NETFIL-processed resins are inherently better suited for high-speed 3D printing because the process reduces nano-scale porosity and free-volume voids within the resin composite. This reduction in nano-porosity limits molecular freedom and suppresses excessive molecular vibrations, particularly under thermal excitation. As a result, the resin reaches a more stable state, where additional heat does not translate into large-amplitude molecular motion or structural instability. This atomic/ molecular-level stabilization allows NETFIL-processed resins to tolerate higher operating temperatures compared to conventional composites. From a 3D- printing manufacturing standpoint, higher vat temperatures directly lower resin viscosity, improving flow, layer replenishment, and wetting—factors that are critical bottlenecks in high-speed 3D printing, especially for high-viscosity composite resins. Consequently, NETFIL enables faster printing speeds, improved print completion rates, and more reliable performance without compromising material properties or damage tolerance.