In-Process Orbiting Laser-Assisted Technique for the Surface Finish in Material Extrusion-Based 3D Printing

Area of Science:

• Additive Manufacturing
• Materials Science
• Surface Engineering

Background:

• Material extrusion 3D printing is widely used for polymers and composites.
• A key limitation is the poor surface finish due to layer-by-layer deposition.
• Improving surface quality is crucial for broader applications.

Purpose of the Study:

• To develop and demonstrate an in-process method for improving the surface finish of 3D printed parts.
• To investigate a thermal radiation-assisted surface reflow technique.
• To quantify the effectiveness of the reflow method in reducing surface roughness.

Main Methods:

• An in-process thermal radiation-assisted surface reflow method was applied during material extrusion 3D printing.
• Optical profilometry was used to characterize surface roughness reduction.
• Scanning electron microscopy (SEM) analyzed surface morphology.
• A thermal camera quantified local heated spot temperatures.

Main Results:

• The surface reflow method significantly improved the surface finish of printed parts.
• Roughness reduction was observed on both flat and curved surfaces.
• The technique effectively smoothed the layer lines characteristic of additive manufacturing.

Conclusions:

• In-process thermal radiation-assisted surface reflow is a viable method to enhance surface quality in material extrusion 3D printing.
• This technique addresses a major drawback of additive manufacturing, leading to higher quality parts.
• Further research can explore optimization for various materials and printing parameters.