DryFusion™ Technology Explained

DryFusion™ is PETGUSA’s proprietary moisture‑removal and polymer‑stabilization process designed to produce filament with ultra‑low moisture content before it ever reaches the spool. The system uses a dual‑drying approach — conditioning the raw polymer before extrusion and stabilizing the filament again after extrusion — all inside a controlled, low‑humidity environment. Unlike traditional filament manufacturing, where moisture is introduced during cooling, handling, and packaging, DryFusion™ isolates every stage from exposure.

The result is a filament that meets the UltraDry™ Certification Standard, delivering consistent, ready‑to‑print performance without drying, ovens, or storage boxes.

Moisture is the single most destructive variable in FDM printing. Even small amounts of absorbed water cause:

bubbling and micro‑voids
stringing and oozing
inconsistent extrusion
weak layer adhesion
surface pitting
dimensional inaccuracies

Traditional filament absorbs moisture during shipping, storage, and even during manufacturing.
DryFusion™ eliminates this problem at the source.

1. Controlled Polymer Conditioning

Raw polymer is conditioned to remove bound moisture before extrusion. This ensures the material begins the process in a stable, low‑moisture state.

2. Precision Thermal Processing

The polymer is extruded under tightly controlled temperatures that prevent reabsorption and maintain molecular stability.

3. Zero‑Exposure Cooling

Instead of cooling in open air — where moisture immediately reenters the material — DryFusion™ uses a controlled environment to maintain dryness during the most vulnerable stage.

4. Controlled‑Environment Spooling

Filament is wound in a controlled, low‑humidity environment designed to minimize moisture exposure during handling.

5. UltraDry™ Sealing

Every spool is sealed in industrial‑grade barrier film with a humidity indicator and vacuum seal, locking in the DryFusion™ moisture level.

6. Certification Testing

Each batch is moisture‑tested to verify it meets the UltraDry™ threshold, then test‑printed to confirm extrusion stability, dimensional accuracy, and surface quality before receiving the UltraDry™ label.

• No drying required — filament is ready to print immediately
• Stronger layer adhesion due to stable polymer chains
• Smoother extrusion with fewer artifacts
• Reduced stringing and oozing
• Improved dimensional accuracy
• Cleaner surface finish
• Longer shelf life
• Industrial‑grade consistency across batches

DryFusion™ is the foundation that makes UltraDry™ Filament possible.

Moisture Control:
- DryFusion: Controlled from start to finish
- Traditional: Exposed to moisture during cooling and handling

Cooling Process:
- DryFusion: Zero‑exposure environment
- Traditional: Open‑air cooling

Packaging:
- DryFusion: Industrial‑grade barrier film with vacuum sealing and engineered UltraDry™ desiccant designed for long‑term moisture stability
- Traditional: Standard vacuum‑sealed bag with basic commodity desiccant

Print Readiness:
- DryFusion: Ready to print
- Traditional: Requires drying

Consistency:
- DryFusion: Certified moisture levels
- Traditional: Highly variable

• Print farms requiring consistent output
• Engineering teams needing strong, reliable prototypes
• High‑speed printers (Bambu, K1, Prusa XL)
• Makers who want perfect prints without drying
• Industrial users needing repeatable results
• Anyone frustrated with moisture‑related failures

• What is UltraDry™ Filament?
• UltraDry™ Certification Standard
• UltraDry vs Traditional Filament
• PETG Troubleshooting Guide