Challenges in electroplating of additive manufactured ABS plastics

Eßbach, Claudia; Fischer, Dirk; Nickel, Dominik

doi:10.1016/j.jmapro.2021.06.037

Cited by 28 publications

(9 citation statements)

References 22 publications

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“…Eßbach et al (2021) have proposed the electroplating of nickel (Ni) to enhance the surface finish of FDM-printed ABS parts. The surface quality of FDM parts was improved by filling the gap of staircasing or surface flaws using electroplated material (Ni).…”

Section: Techniques For Improving the Surface Quality Of Additively M...mentioning

confidence: 99%

A comprehensive review on surface quality improvement methods for additively manufactured parts

Hashmi

Mali

Meena

2022

RPJ

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Purpose The purpose of this paper is to study the functionality of additively manufactured (AM) parts, mainly depending on their dimensional accuracy and surface finish. However, the products manufactured using AM usually suffer from defects like roughness or uneven surfaces. This paper discusses the various surface quality improvement techniques, including how to reduce surface defects, surface roughness and dimensional accuracy of AM parts. Design/methodology/approach There are many different types of popular AM methods. Unfortunately, these AM methods are susceptible to different kinds of surface defects in the product. As a result, pre- and postprocessing efforts and control of various AM process parameters are needed to improve the surface quality and reduce surface roughness. Findings In this paper, the various surface quality improvement methods are categorized based on the type of materials, working principles of AM and types of finishing processes. They have been divided into chemical, thermal, mechanical and hybrid-based categories. Research limitations/implications The review has evaluated the possibility of various surface finishing methods for enhancing the surface quality of AM parts. It has also discussed the research perspective of these methods for surface finishing of AM parts at micro- to nanolevel surface roughness and better dimensional accuracy. Originality/value This paper represents a comprehensive review of surface quality improvement methods for both metals and polymer-based AM parts. Graphical abstract of surface quality improvement methods

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Section: Techniques For Improving the Surface Quality Of Additively M...mentioning

confidence: 99%

A comprehensive review on surface quality improvement methods for additively manufactured parts

Hashmi

Mali

Meena

2022

RPJ

View full text Add to dashboard Cite

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“…One of its main advantages is that it allows the fabrication of parts of rather complex shapes with low investment costs, without large quantities of scrap, and in a simpler way compared to the more traditional forming techniques. [ 3,4 ] On the other hand, parts manufactured via FFF have some well‐known problematic issues, the main one being the lengthy manufacturing procedure, but noteworthy also are the inferior surface aesthetic quality [ 5–7 ] and the lower mechanical properties. [ 7–12 ]…”

Section: Introductionmentioning

confidence: 99%

Infill Density Effects on the Mechanical and Thermal Properties of Copper‐Plated 3D Printed Parts

Ludergnani,

Fredi,

Malagutti

et al. 2023

Macro Materials & Eng

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Fused Filament Fabrication (FFF) is a 3D‐printing technique that enables the production of complex geometries with a high level of customization at low cost. The poor mechanical properties of FFF‐printed parts often undermine the application of this technology for structural purposes. To overcome this limitation, a two‐step metallization method is performed to deposit a copper layer on the exterior of an Acrylonitrile–Butadiene–Styrene (ABS) substrate, using a non‐toxic and cost‐effective plating solution. Electroplating over the exposed grid infill, at various densities, is exploited to improve the load transfer between copper and ABS. The resulting samples are characterized mechanically and thermally, and finite element modeling simulations are used to better understand the characterization results. It is found that an infill of 50–60% provides the best compromise between mechanical performance and thermal conductivity because the infill density is low enough to allow copper penetration into the material to create a strong mechanical interlocking with ABS, yet high enough to create multiple conductive bridges through the thickness of the sample. This study demonstrates the effectiveness of electroplating as a post‐processing technique to simultaneously enhance the mechanical and thermal properties of FFF‐printed parts and provides insights into the optimal design parameters for achieving this goal.

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“…By understanding their transfer physics from multi-phase fluid can open-up an economical manufacturing process for complex architecture including porous solid 20 , 21 . Such understanding can be directly implemented to novel particle sorting technique of different size and density distribution 39 , 40 , inorganic material coating on 3D printed polymer surface 41 , acoustic meta-surface for hypersonic boundary layer transition and stabilization 42 , dust mitigation in both hydrophobic and hydrophilic surfaces 43 surface wettability and flowability improvement for medical devices 44 and thin-surface wicks for heat and mass transfer 45 – 47 . The micro-scale inorganic particles have reduced surface area and higher density, making them negatively buoyant in the LCS and challenging to yield high solid transfer due to the density mismatch causing them to settle in suspension.…”

Section: Introductionmentioning

confidence: 99%

Micro-particle entrainment from density mismatched liquid carrier system

Shovon

Alam

Gramlich

et al. 2022

Sci Rep

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Micro-scale inorganic particles (d > 1 µm) have reduced surface area and higher density, making them negatively buoyant in most dip-coating mixtures. Their controlled delivery in hard-to-reach places through entrainment is possible but challenging due to the density mismatch between them and the liquid matrix called liquid carrier system (LCS). In this work, the particle transfer mechanism from the complex density mismatching mixture was investigated. The LCS solution was prepared and optimized using a polymer binder and an evaporating solvent. The inorganic particles were dispersed in the LCS by stirring at the just suspending speed to maintain the pseudo suspension characteristics for the heterogeneous mixture. The effect of solid loading and the binder volume fraction on solid transfer has been reported at room temperature. Two coating regimes are observed (i) heterogeneous coating where particle clusters are formed at a low capillary number and (ii) effective viscous regime, where full coverage can be observed on the substrate. ‘Zero’ particle entrainment was not observed even at a low capillary number of the mixture, which can be attributed to the presence of the binder and hydrodynamic flow of the particles due to the stirring of the mixture. The critical film thickness for particle entrainment is $${h}^{*}=0.16a$$ h ∗ = 0.16 a for 6.5% binder and $${h}^{*}=0.26a$$ h ∗ = 0.26 a for 10.5% binder, which are smaller than previously reported in literature. Furthermore, the transferred particle matrices closely follow the analytical expression (modified LLD) of density matching suspension which demonstrate that the density mismatch effect can be neutralized with the stirring energy. The findings of this research will help to understand this high-volume solid transfer technique and develop novel manufacturing processes.

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Challenges in electroplating of additive manufactured ABS plastics

Cited by 28 publications

References 22 publications

A comprehensive review on surface quality improvement methods for additively manufactured parts

A comprehensive review on surface quality improvement methods for additively manufactured parts

Infill Density Effects on the Mechanical and Thermal Properties of Copper‐Plated 3D Printed Parts

Micro-particle entrainment from density mismatched liquid carrier system

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