Surface modification of prototypes in fused filament fabrication using chemical vapour smoothing

Mu, Mulan; Ou, Chien Hui; Wang, Junjie; Liu, Yongliang

doi:10.1016/j.addma.2019.100972

Cited by 33 publications

(30 citation statements)

References 22 publications

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“…They also developed a mathematical model for the prediction of the average surface roughness of the treated parts. Mu et al [ 20 ] compared the effect of different mixtures of acetone and ethyl acetate to improve the surface coarseness of ABS specimens with different building orientations and concluded that the tensile strength of samples treated with the acetone or the mixed vapor decreased with increasing the exposure time. The best results in terms of mechanical performance were obtained when vapors of pure ethyl acetate were used.…”

Section: Introductionmentioning

confidence: 99%

A Comparative Analysis of Chemical, Thermal, and Mechanical Post-Process of Fused Filament Fabricated Polyetherimide Parts for Surface Quality Enhancement

2021

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Additive manufacturing technologies are increasingly being used in production systems because they shorten product development time and production cost, but surface integrity remains a limitation to meet the standards set by conventional manufacturing. In this research article, two chemical, one thermal, and three mechanical finishing operations are proposed to post-process fused filament fabricated Ultem 9085 parts. Their effects on the parts’ surface quality and dimensional accuracy (changes in their width, height, length, and mass) are examined through optical and electron scanning microscopy, and the advantages and disadvantages of each method are discussed. Microscope evaluation has proven to be a powerful tool to observe apparent differences and understand the nature of different morphological changes. Results indicate that chemical and thermal treatments and ball burnishing are good candidates to significantly enhance the finish of the parts, despite requiring the use of solvents or provoking dimensional changes to the parts. The effects of abrasive mechanical treatments are more moderate at a macroscopic scale, but the surface of the filaments suffers the most remarkable changes.

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Section: Introductionmentioning

confidence: 99%

A Comparative Analysis of Chemical, Thermal, and Mechanical Post-Process of Fused Filament Fabricated Polyetherimide Parts for Surface Quality Enhancement

2021

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“…The surface quality of the 3D printed parts has been studied in the literature for Fused Filament Fabrication (FFF) [18][19][20][21][22][23][24][25][26], Micro-Stereolithography [27], Laminated Object Manufacturing [28] and Selective Laser Sintering (SLS) parts [29][30][31]. Mathematical [18,21], empirical [22] and learning-based predictive [26] models have been presented, considering the 3D printing parameters [24,28], for the surface roughness of FFF parts, while nondestructive characterization methods are used to determine the surface roughness of SLS parts [31].…”

Section: Introductionmentioning

confidence: 99%

Surface Roughness Investigation of Poly-Jet 3D Printing

et al. 2020

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An experimental investigation of the surface quality of the Poly-Jet 3D printing (PJ-3DP) process is presented. PJ-3DP is an additive manufacturing process, which uses jetted photopolymer droplets, which are immediately cured with ultraviolet lamps, to build physical models, layer-by-layer. This method is fast and accurate due to the mechanism it uses for the deposition of layers as well as the 16 microns of layer thickness used. Τo characterize the surface quality of PJ-3DP printed parts, an experiment was designed and the results were analyzed to identify the impact of the deposition angle and blade mechanism motion onto the surface roughness. First, linear regression models were extracted for the prediction of surface quality parameters, such as the average surface roughness (Ra) and the total height of the profile (Rt) in the X and Y directions. Then, a Feed Forward Back Propagation Neural Network (FFBP-NN) was proposed for increasing the prediction performance of the surface roughness parameters Ra and Rt. These two models were compared with the reported ones in the literature; it was revealed that both performed better, leading to more accurate surface roughness predictions, whilst the NN model resulted in the best predictions, in particular for the Ra parameter.

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“…The layer resettlement marks are clearly visible in SEM images. The material flows from heightened polymers layers and flows into the voids [ 33 ]. After cooling, it gets settled as smooth layers which gives high quality surface.…”

Section: Resultsmentioning

confidence: 99%

Predictive modeling of surface and dimensional features of vapour-smoothened FDM parts using self-adaptive cuckoo search algorithm

et al. 2022

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Despite numerous advantages of fused deposition modeling (FDM), the inherent layer-by-layer deposition behavior leads to considerable surface roughness and dimensional variability, limiting its usability for critical applications. This study has been conducted to select optimum parameters of FDM and vapour smoothing (chemical finishing) process to maximize surface finish, hardness, and dimensional accuracy. A self-adaptive cuckoo search algorithm for predictive modelling of surface and dimensional features of vapour-smoothened FDM-printed functional prototypes has been demonstrated. The chemical finishing has been performed on hip prosthesis (benchmark) using hot vapours of acetone (using dedicated experimental set-up). Based upon the selected design of experiment technique, 18 sets of experiments (with three repetitions) were performed by varying six parameters. Afterwards, a self-adaptive cuckoo search algorithm was implemented by formulating five objective functions using regression analysis to select optimum parameters. An excellent functional relationship between output and input parameters has been developed using a self-adaptive cuckoo search algorithm which has successfully found the solution to optimization issues related to different responses. The confirmatory experiments indicated a strong correlation between predicted and actual surface finish measurements, along with hardness and dimensional accuracy.

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Surface modification of prototypes in fused filament fabrication using chemical vapour smoothing

Cited by 33 publications

References 22 publications

A Comparative Analysis of Chemical, Thermal, and Mechanical Post-Process of Fused Filament Fabricated Polyetherimide Parts for Surface Quality Enhancement

A Comparative Analysis of Chemical, Thermal, and Mechanical Post-Process of Fused Filament Fabricated Polyetherimide Parts for Surface Quality Enhancement

Surface Roughness Investigation of Poly-Jet 3D Printing

Predictive modeling of surface and dimensional features of vapour-smoothened FDM parts using self-adaptive cuckoo search algorithm

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