Influence of different post-processing methods on surface topography of fused deposition modelling samples

Abstract

Additive Manufacturing (AM) is gaining prominence due to its massive advantage in fabricating components without any geometrical limitations. The most widely used AM technique is Fused Deposition Modelling (FDM). FDM is an extrusion-based AM mostly focused on producing functional prototypes and in some cases as an end-product. One of the most common challenges associated with FDM is its reduced dimensional accuracy and surface quality. A fair amount of research has been carried out to identify the factors affecting print quality and measures to reduce surface roughness. On a few occasions, it is still necessary to achieve higher precision and quality to meet the standards set by conventional manufacturing. Hence, post-processing is employed as an additional step to reach the finish required. This paper focuses on enhancing the surface quality of FDM parts by subjecting it to Acetone vapour smoothening, Shot-blasting and Laser-assisted finishing post-processing methods. A comparative study is presented in this paper, where surface produced by different post-processing methods were compared to the reference injection moulding components. The results suggest that the acetone-based process has the best surface finish compared to the other two means; however, it leaves a very glossy appearance to the part. Shot blasting is very aggressive, and blasting time has a strong influence on the part quality. Laser-assisted finishing slightly ignites the top layer during melting leading to discolouration of the part. The optimum solution was found to be combining the post-processes, which not only reduced the roughness but also enhanced the aesthetic properties of the product.

Fused deposition modelling: Current status, methodology, applications and future prospects

“…Research has been carried out to identify the factors affecting print quality and measures to reduce surface roughness by post-processing as an additional step to reach the finish required [189]. Thus, many post-processing methods to improve surface roughness in FDM parts have been investigated and applied, and can be categorized into two typeschemical and mechanical processes [190].…”

“…A novel post-processing tool, namely thermally assisted finishing tool (TAFT) has been designed and developed for thermally assisted finishing (TAF) of FDM built parts on CNC milling machines to improve their surface finish conditions [202]. The surface quality of FDM parts has also been enhanced by subjecting them to acetone chemical vapour smoothing (CVS), shot-blasting and laser-assisted finishing post-processing methods [189]. Improvements in surface roughness and dimensional accuracy of biomedical implants have been achieved by combining FDM, CVP and investment casting, which is a renowned process for producing dimensionally accurate and highly finished casts [203].…”

Property enhancement approaches of fused filament fabrication technology: A review

“…While the laser did reduce surface roughness and provide superior isotropic profiles, shot blasting helped to eliminate the burnt top layer and restore the product's natural color. [151] F I G U R E 4 SEM image of the 3D printed surface (A) before polishing and (B) after polishing 3.3 | Thermal processes…”

“…While the laser did reduce surface roughness and provide superior isotropic profiles, shot blasting helped to eliminate the burnt top layer and restore the product's natural color. [ 151 ]…”

Mechanical Characterization and Thermodynamic Analysis of Laser-Polished Landscape Design Products Using 3D Printing

“…A model set of buildings in Qinhuangdao, China, was printed using FDM and PLA materials, which can be seen in Figure 1 a,b. Unfortunately, high surface roughness and porosity usually occur in such freeform-fabricated components due to the staircase effect, non-uniform temperatures, and thermal shrinkage or expansion [ 16 , 17 , 18 ], which can be seen in Figure 1 c. Therefore, such products usually requires additional post-treatment or parameter optimization to meet landscape design requirements.…”