Improving surface smoothness in FDM parts through ironing post-processing

Abstract

Additive manufacturing using fused deposition modelling (FDM) is an affordable and efficient way to produce functional parts and prototypes. However, the FDM-manufactured parts, particularly those made of polylactic acid (PLA), has some drawbacks regarding accuracy and surface finish. To address this, post-processing techniques such as ironing can be applied. However, little is known about the effect of ironing process parameters on surface roughness, and there is a lack of comparative studies on contact and non-contact measurement methods. This study aims to address these gaps by investigating the impact of path speed, ironing spacing, and flow rate on the surface roughness of FDM-produced PLA samples using both contact and non-contact measurement methods. The results show that the ironing process can lead to a significant reduction in surface roughness values, and careful optimization of process parameters can further minimize roughness. The study highlights the advantages and limitations of contact and non-contact methods for surface roughness analysis and provides guidance on selecting the appropriate method for a given application and material.

Optimizing surface roughness in soft pneumatic gripper fabricated via FDM: experimental investigation using Taguchi method

“…Alzyod et al . investigated the effect of path speed, ironing spacing and flow rate on the surface quality of PLA samples fabricated with FDM using contact and non-contact measurement methods (Alzyod et al. , 2023).…”

“…In another study, they observed that PLA had better surface quality than ABS material. Alzyod et al investigated the effect of path speed, ironing spacing and flow rate on the surface quality of PLA samples fabricated with FDM using contact and non-contact measurement methods (Alzyod et al, 2023). The results demonstrated that the ironing process can lead to an important reduction in surface roughness values, and careful optimization of process parameters can further minimize roughness.…”

Investigating the Impact of Productivity on Surface Roughness and Dimensional Accuracy in FDM 3D Printing

“…PLA (Polylactic Acid) is a commonly chosen material for numerous 3D printing applications due to its excellent dimensional stability, minimal shrinkage, and ease of printing. PLA is a thermoplastic derived from renewable resources and is recognized for its ability to produce high-quality prints with a smooth surface finish (Alzyod et al, 2023;Fekete et al, 2021;). While the properties of PLA can vary depending on the specific manufacturer, the ranges provided in Table 1 offer a good understanding of the material's general characteristics.…”

Ironing Process Optimization for Enhanced Properties in Material Extrusion technology using Box-Behnken Design

“…However, in this study, we aim to study the effect of using the ironing post-processing technique after every printed layer on the mechanical properties of PLA components made utilizing the MEX process. Ironing has shown promising results in improving surface quality by reducing surface roughness and decreasing the visibility of layer lines [34]. By performing ironing as a processing step, the aim is to improve the adhesion between layers and enhance the mechanical properties of the part by reducing the occurrence of interlayer voids and delamination.…”