Additive Manufacturing: Post Processing Methods and Challenges

Abstract

Additive Manufacturing (AM) has shown great potential for efficient realization of complicated microdevices fabricated with higher freedom of design and made from a wide variety of materials suiting to their specific target functionalities. Capability of generation of components with reduced weights, higher part consolidation, greater customization offered along with minimal waste generation are its advantages over conventional manufacturing processes. The AM built parts, however, need to undergo relevant post processing techniques to render them fit for their end product application. The paper attempts to classify the post processing techniques and emphasize their applicability to specific AM methods, generalized procedure as well as the recent improvements undergone. The post processing techniques have been categorised as methods for support material removal, surface texture improvements, thermal and non-thermal post processing and aesthetic improvements. The main challenges to the expansion of additive manufacturing have been discussed which highlight the future, scope of improvement and research required in the area of appropriate tool path development and product quality with regards to surface roughness, resolution and porosity levels in the built part.

Developing a YOLOv3-Based Neural Network to Enable Digital Cameras to Detect Features on the Reflective Surface of Objects in Robotic Applications: A Low-Computational Approach with a New Public Dataset

“…This is particularly evident in the need for post-process machining of additive manufactured parts to improve surface finish and geometric accuracy as noted by Lane et al [15]. Mishra et al [16] further emphasizes the importance of post-processing techniques, categorizing them into methods for support material removal, surface texture improvements, thermal and non-thermal post-processing, and aesthetic improvements. Schneberger et al [17] underscores the need for a comprehensive framework for the development of hybrid AM parts, which includes post-processing, testing, and life cycle monitoring.…”

Overcoming the post-processing barriers for 3D-printed medical models

“…2.4 Post-processing barriers for 3D-printed medical model Importantly, post-processing significantly slows down 3DPMM delivery (Chohan and Singh, 2017;Gibson et al, 2021a). More research is needed to analyze and find an alternative solution for fast production (Shen et al, 2020;Mishra et al, 2021). This study analyzes existing literature and identifies 11 post-processing barriers for 3DPMM production, as briefly discussed below.…”

“…Chemical finishing includes manual painting, acetone dipping, electroplating and vapour smoothing (Boparai et al , 2016; Chohan and Singh, 2017; Niaki and Nonino, 2018). After printing by FDM, companies typically perform post-processing activities such as sanding, gross support removal and dissolving support, followed by rinse and dry (Chohan and Singh, 2017; Mishra et al , 2021); Figure 1 depicts post-processing steps for 3DPMM after FDM printing.…”

“…Kuczko et al (2017) studied the accuracy of post-processing prototype testing on FDM-printed models to compare 3D-printed parts before and after treatment by 3D scanning methods. Mishra et al (2021) discussed post-processing methods such as non-thermal and thermal post-processing, texture improvements, support material removal and aesthetic improvements. Nsengimana et al (2019) explored post-processing effects on the accuracy of FDM-printed ABS parts.…”

Parametric Modeling and Optimization of Dimensional Error and Surface Roughness of Fused Deposition Modeling Printed Polyethylene Terephthalate Glycol Parts

“…In recent years, additive manufacturing has grown rapidly to produce a variety of functional parts involving complex geometries with specific functionalities made from a wide range of materials. In contrast to traditional machining, where material is carved out from a block using suitable cutting tools to obtain the desired geometry [ 1 , 2 ], fused deposition modeling (FDM) is an extrusion-based AM process involving the layer-wise deposition of thermoplastic filaments in a semi-liquid state [ 3 , 4 , 5 ] using a computer-controlled deposition nozzle [ 6 ]. FDM allows researchers to obtain complex yet flexible and functional parts from a standard tessellation language (STL) file quickly, with high quality and a wide range of engineering thermoplastic materials [ 1 ], along with offering reduced assembly costs [ 7 ].…”