Vapour polishing of fused deposition modelling (FDM) parts: a critical review of different techniques, and subsequent surface finish and mechanical properties of the post-processed 3D-printed parts

Abstract

Fused deposition modelling (FDM), one of the most commonly used additive manufacturing techniques in the industry, involves layer-by-layer deposition of melted material to create a 3D structure. The staircase and beading effect caused by the printing process and temperature variation cause delamination and poor surface finish in FDM-printed parts. This hinders the use of these specimens in various applications, which are then usually resolved using pre-processing and post-processing techniques. Higher surface finish in pre-processing is achieved by increasing the resolution, changing layer thickness and optimizing build orientation. However, this increases the processing time considerably. On the other hand, post-processing techniques involve different processes such as mechanical, chemical, thermal and hybrid methods but can affect the mechanical and structural properties of the printed components. This review paper analyses three different aspects in the area of improving the surface finish of FDM-printed parts. First, this article reviews the state-of-the-art attempts made to improve the surface finish of FDM-printed parts concentrated mainly on different vapour polishing techniques and their respective merits and demerits. Second, it focuses on the changes in mechanical properties before and after polishing. Finally, the paper explores the development in the 3D printing of thermosets and composite materials and their post-processing processes and process parameters.

Parametric Optimization of FDM Process for PA12-CF Parts Using Integrated Response Surface Methodology, Grey Relational Analysis, and Grey Wolf Optimization

“…Figure 4 a shows that the lower layer thickness and higher infill density have lower Ra. Larger layer height results in a rougher surface finish because each layer is thicker, leading to a more noticeable stair-stepping effect [ 45 ]. With high infill density, a dense structure is formed with fine layers adhering to each other, thus reducing porosity and providing a smooth surface [ 46 ].…”

Manufacture of thermoplastic molds by fused filament fabrication 3D printing for rapid prototyping of polyurethane foam molded products

“…In a recent review work, the most common post-processing treatments are cited for improving the surface roughness of parts manufactured in PLA by FFF/FDM. Among these treatments, the use of vapors or immersion in dichloromethane, chloroform or ethyl acetate, although it has been shown that the use of ethyl acetate is more advisable through either of the two techniques with the advantage of its reduced toxicity, availability and economical price (Lavecchia et al , 2022; Mathew et al , 2023).…”

Enhancing Properties of 3D Printed Polymers: A Review of Recent PostProcessing Methods

“…However, regardless of the method chosen, thorough cleaning of parts post-processing is crucial to remove any debris or residue. This step ensures the final surface quality meets the desired standards [25,38,40,41].…”