Experimental assessment of surface roughness of fused deposition modelling parts and method of improvement

The surface roughness assessment of 3D printed parts with Fused Deposition Modelling (FDM) has been performed on Acrylonitrile Butadiene Styrene, Poly Lactic Acid, Polycarbonate, Nylon, Polypropylene, Co-polyester. Three different geometries were selected i.e., Cube, Cone and Strip to evaluate the effect of build geometry and material on the surface roughness of 3D printed parts of FDM technology. It has been revealed from the roughness measurements of cube and cone samples, that roughness values are higher as compared to strip sample and in almost the same range in the build direction irrespective of the shape. The variation of surface roughness as a function of nozzle temperature has also shown that it is also dependent on the nozzle temperature while keeping other parameters constant. The experiments on the improvement in the surface quality of FDM parts was also performed using chemical and physical methods. Tetrahydrofuran, Dichloromethane and Acetone were found compatible with polycarbonate to improve surface without compromising the geometrical shape. Similarly Acrylonitrile Butadiene Styrene had excellent response to Acetone vapour smoothing both in terms of surface roughness and part symmetry. The surface roughness of PLA was also improved after treatment with Tetrahydrofuran. Co-Polyester, although had good surface after treatment with Tetrahydrofuran and Dichloromethane, but the part symmetry was disturbed.