POST PROCESSING FOR FDM (Fused Deposition Modelling) 3D

PRINTED PARTS

Introduction

• FDM 3D printing is best suited for cost effective prototypes produced with short
lead time. Layer lines are generally present on FDM prints.
• Making post processing an important step if a smooth surface is required. Some
post processing methods can also add strength to prints helping to mitigate the
anisotropic behavior of FDM parts.

1. Support Removal
Support removal is typically the first stage of postprocessing for any 3D printing
technologies that require support to accurately produce parts. Support can generally be
separated into 2 categories; standard and dissolvable. Unlike the other postprocessing
methods discussed in this article support removal is a mandatory requirement and does
not produce an improved surface finish.

Part

Support
Material

Part

After
removing
Fig
supports
 Fig. Before and After Support Removal

Standard support removal

Tool kit
• Needle nose pliers
• Dental pick set

Process: Support material can generally be removed from the print with little effort, and
cleaning of support material in hard to reach places (like holes or hollows) can be
achieved with dental picks and needlenose pliers. Well placed support structures, and
proper print orientation, can greatly reduce aesthetic impact of support material on the
final print.

Pros
• Does not alter overall geometry of part.
• Very quick.
Cons
• Does not remove any layer lines, striations, or blemishes on the print surface.
• If support structures leave behind excess material or marks, the accuracy and
appearance of the print is diminished.

Dissolvable support removal

Tool kit
• Solvent safe container
• Solvent
• Ultrasonic Cleaner (optional)

Process: Standard dissolvable support materials are removed from a print by placing
the print in a bath of the appropriate solvent until the support material dissolves. The
support is typically printed in:
• HIPS High Impact Polystyrene (usually associated with ABS - Acrylonitrile
butadiene styrene )
• PVA Poly Vinyl Alcohol (usually associated with PLA-Polylactic acid )
• HydroFill
Glass storage containers, like a mason jar, make excellent vessels for dissolving with
Limonene. For dissolving in water, any nonporous container will work. For HIPS/ABS
prints, a bath in a 1:1 ratio of (R)

limonene and isopropyl alcohol works very well for rapid support removal. Many other
support materials, such as PVA (used with PLA) and HydroFill (PLA and ABS), simply
dissolve in plain water.

2. CLEANING PROCESS
Rinsing
A basic rinse can go a long way in keeping your prints clean. Residual glue from first layer
adhesion, small blobs, stringing, and other undesirable protrusions can all be washed away
just by scrubbing the print.

How to Perform

• Rinse the print using soapy water or isopropyl alcohol. Simply drop the print in the
liquid and scrub using a sponge or paper towel. Be careful not to scrub too hard, as
you could potentially discolor or damage the part.
• purchase a dedicated wash-station to clean the prints automatically. While many of
these solutions are designed for SLA 3D prints, they will work great for rinsing FDM
parts too.
3. Sanding
It is one of the simplest methods for post-processing of FDM 3D printed parts. It
is similar to sanding wood objects but it requires a lot of effort. The sanding has
to be carried out in successive stages starting from low grit sandpaper (usually
150 grit) and moving towards higher grit sandpapers like 400grit, 600 grit till 2000
grit, or even more depending on the requirement.

While sanding the part, friction is created between the sandpaper and the surface
generates heat, which may have a negative impact on the fine features of the
print. To prevent this, simply wet your part before sanding to absorb any excess
heat.

The drawback of sanding is the amount of time and effort it takes. Additionally,
the material is unequally removed so the dimensional accuracy of the part will be
hampered.

Apart from this, the fine particles of the material are released into the air and
can enter the lungs while breathing so it is recommended to use a mask while
sanding 3D printed parts.
4. Polishing
• Polishing can be achieved by using a buffing wheel using a Dremel tool. A
separate 3D printing Dremel toolkit is available for makers and creators to buy.

• Polishing is done only after sanding. After sanding, rinse the parts and make
them particle-free. Use a cloth and move it in a circular motion until you’re
satisfied with the result. This will enhance the finish of the print.

• Polishing 3D prints can be done with plastic polishers and tools available at
almost every hardware store.
 INSPECTION TECHNIQUES & DEFECTS DETECTION INVOLVED IN
ADDITIVE MANUFACTURING / 3D PRINTING

Traditional Tools Adapted for AM / 3D Printing

A widespread set of measurement options are available for quality inspections, from the traditional
manual tools to digital industrial equipment. Starting from the basics, manual instruments like calipers
and gauge kits, in comparison to other options, are affordable, straightforward, and widely accepted.
However, each of these tools deals with a specific geometrical feature (i.e., external length, diameter,
corner angles). Simply put, not the most versatile options. But, perhaps the most significant downside
these tools have is the fact that all the quality data registration happens manually. Consequently,
metrology inspections can become laborious and inefficient tasks. In contrast, two of the main reasons
industries are adopting additive manufacturing are, on the one hand, to enable more geometrical
versatility and, on the other hand, to boost production workflows via digitization.

INSPECTION TECHNIQUES

1. Coordinate Measuring Machine

he necessity to reach higher standards has lead industries to adopt CMMs (Coordinate Measurement
Machines). These machines can replicate digital point clouds throughout their extremely precise
contact probes with exact measurements of very intricate geometries like those of airfoils. Moreover,
this enables direct interaction within CAD environments, which opens new possibilities for data
analysis. Digital tools can streamline tolerance verification processes by comparing the deviations of
manufactured parts by aligning them with their respective nominal CAD design. Meanwhile, all that
inspection data can be directly stored and processed in a centralized system. All in all, CMMs are
marvelous; still, they have limitations too. Compared to other methods, CMMs inspection cycles are
slow, they have low portability, and since they are contact-based, they heavily rely on fixtures. Now,
this allows us to appreciate light-based 3D scanners as valuable alternatives to CMMs.

2. Optical 3D Scanners

Regardless of which particular scanner technology we’re talking about – photogrammetry, structured
light, or laser triangulation – 3D scanners capture coordinate points at incredibly high rates without
even needing to touch the object. So then, using the principles of optics brings big advantages to
scanning, but paradoxically, also big disadvantages in some instances. Limitations are predominantly
interference of external light settings, while surfaces with reflective, transparent, and matte dark
characteristics can disrupt the quality of data collection. All in all, considering the accelerated rates at
which scanner manufacturers are working to solve these problems, optical 3D scanners have,
undoubtedly, a promising future in manufacturing.

Optical 3D Scanner

3. Computed Tomography

Apart from medical insights, CT scans have also been, for many years, the object of desire for
inspectors in manufacturing environments with strict quality requirements. Why is that? Well, by
leveraging x-ray imaging, CT scans can generate complete views of internal details fast and with
outstanding accuracies. Furthermore, all this data can be exported as 3D density maps with thorough
information on the product’s quality. But, there’s more; CT scanning goes beyond just metrology, it is
also ideal for inspecting defects like cracks, delamination, voids, contamination, and local porosities
without even touching the part.

CT scanners have much broader capabilities than other non-destructive quality tests like those with
penetrant liquids, eddy currents, magnetic particles, and ultrasound. Nonetheless, CT scanners might
be way too expensive for most applications, not to mention the hazards involved with x-rays
emissions. Due to the difficulties of having CT equipment in-house, many third-party consultant
companies, like Visiconsult, provide CT inspection services.

4. In- Situ Inspection

Considering that we still need to learn more about AM processes in order to develop standards and to
establish serial production adoption with full confidence, there’s clearly a necessity to speed up data
collection. All of the practices we glanced at so far would require laborious inspections task separate
from the production process itself. But, given the ongoing advancements in sensors, closed-loop
automation, artificial intelligence, machine learning, and cloud computing, it’s no surprise that AM
leading innovators are already implementing these principles for in-situ inspection processes, in other
words, scanners and inspection technology already imbedded into the 3D printer.

So basically, it works like this; sensors capture data as each layer forms. Afterwards, AI can take all
that information in real-time to make comparisons, deliver analytics, stop the processes if errors are
detected, and, most important, optimize printing parameters through a learning history. Most of the
firms involved in this trend focus on implementing these solutions for metal PBF processes.
TRADITIONAL NON- DESTRUCTIVE DEFECT DETECTON TECHNOLOGY

1. Infrared Imaging Defect Detection

The principle of infrared thermal imaging technology displays the shape and contour of
defects through the thermal radiation intensity of the additively manufactured workpiece. The
thermal radiation difference between the defects and the surrounding materials makes the
defects stand out in infrared images. According to the theoretical results of the thermoelastic
effect in the isotropic homogeneous body, metal samples with different defects have different
material properties. Defects will affect the heat conduction in the metal samples, and then
affect the temperature field in the samples. Using a certain method to input heat into the
samples can detect the temperature field of the samples through various infrared sensors to
obtain defect information. Using this conclusion, it is possible to use infrared thermal
imaging cameras to detect the surface temperature field of additively manufactured objects,
find areas with abnormal temperatures, and determine the location of defects.

2. Penetration Defect Detection

Penetration defect detection is a non-destructive testing method that uses capillary

phenomena to inspect the surface defects of materials. Its working principle is simple: A
penetrant containing fluorescent or colored dyes is applied to the surface of the workpiece.
Under capillary action, the penetrant infiltrates and settles into surface defects. Any excess
penetrant on the surface of the workpiece is removed after drying. A developer is then
applied on the surface of the workpiece and reacts with the penetrant under the effect of a
light source, which displays the trace of the penetrant and the defects. Penetrants containing
fluorescent agents are significantly more sensitive for defect detection than ordinary
penetrants. The factors that affect the sensitivity of penetrant detection include imaging
reagents, penetrant performance, and the effects of defects themselves. Fluorescent penetrant
detection technology is easily affected by the structure of additively manufactured
workpieces, and it is highly sensitive to surface-opening defects and intuitive results.
Penetration testing methods are not suitable for testing porous or rough additively
manufactured parts that have not undergone post-processing or polishing.

3. Eddy Current Defect Detection

Eddy current testing is a non-destructive testing method that uses the principle of
electromagnetic induction to identify defects in conductive materials by measuring the
changes in induced eddy currents. Exciting a coil applies an alternating magnetic field to the
test piece and generates an eddy current under the action of the alternating magnetic field.
The current in the coil changes due to the eddy current reaction. The eddy current change can
be measured, thereby obtaining the status information of the test piece defect. The eddy
current distribution and size are determined by factors such as the shape and size of the coil,
the AC frequency, conductivity, permeability; the shape and size of the test piece, the
distance between the test piece and the probe, and the surface defects of the test piece.
Therefore, the detected eddy current conveys information about the material, defect, shape,
and size of the test piece. The main factors that affect the accuracy of eddy current detection
include the type and parameters of the coil and the material and contour of the detection part.
Eddy current testing technology can be used in harsh environments. It meets some of the
requirements of AM for nondestructive testing and is suitable for detecting defects such as
cracks and non- fusion pores.
4. Ultrasonic Defect Detection

Ultrasonic testing refers to a non-destructive testing method that uses ultrasonic waves to
inspect the internal defects of metal components. It uses a transmitting probe that emits
ultrasonic waves to the surface of a component through a couplant. When the ultrasonic
waves propagate inside the component, they emit different reflected signals as they encounter
different interfaces. The defects inside the component can be identified based on the time
difference between the transmission of different reflected signals to the probe. The height and
position of the echo signal displayed on the phosphor screen reveal the size, position, and
general nature of the defect. Ultrasonic testing is more sensitive to cracks, incomplete
penetration, and infusion defects and less sensitive to pores and slag inclusions. It is also less
intuitive, easy to miss, and insensitive to nearsurface defects. The propagation of ultrasonic
waves in additively manufactured parts will be affected by defects, so it can reflect defect
information in parts. This method is mainly used to detect defects such as pores and cracks.
 FLATNESS OR WARP CHECK FOR FDM 3D PRINTED PARTS

Filaments used in FDM 3D printing are usually thermoplastics, materials that can
melt (turning to liquid), cool (turning to solid), and still keep their mechanical
properties. In 3D printing, we heat the filament to somewhere beyond its melting
point so that, in its liquid form, it can be extruded onto a build plate.

While heating, thermoplastics expand, shrinking again when they cool down and
return to a solid. This transformation creates some movement in extruded plastics,
which is the root of 3D print warping: colder layers pulling on hotter layers as they
contract. And if this occurs when the hotter layers are below the colder ones, the 3D
printed object will be forced to let go of its grip on the build surface, and curl
upwards.

To make matters worse, the problem can (literally) pop up after a good portion of the
print job is already finished, ruining an otherwise perfect print!

If we could keep the whole 3D printed model at the exact same temperature at all
times, not even a tiny corner of the model would try to warp. But this is pretty much
impossible. What we can do is try to keep the 3D printed model’s temperature as
even as possible. And we can also do our best to convince the model to hold on to
the build surface like its life depends on it!
Below, we’ve covered three methods to attempt to combat warping and save your
prints.

Rare Case: Print Bed Warping

Some hobbyists have reported the print bed warping along with the print, and this
seems to mostly occur with large prints (with broad first layers) on spring steel
surfaces. This likely occurs because the large print accumulates even more warping
forces than usual and the flexible build plate – though sticking well to the print –
bends along with it! If you experience this problem (or are worried you might) and
aren’t able to apply the following solutions to mitigate it, consider switching to
a glass build plate.

Temperature, not just of the filament but of the bed and the surrounding air, is
perhaps the most important factor in preventing warping. Here are some tips on
maintaining the optimal temperature conditions:

• Use a heated bed: This helps even out the temperature in the model. A heated
build plate also helps with bed adhesion. Usually, the filament manufacturer
gives recommended bed temperatures.
 • Use an enclosed print chamber: This helps maintain a constant ambient
temperature throughout the printing process. If your printer doesn’t have an
enclosure, check out our article on how to build your own.
• Control room temperature: Do this by keeping windows and doors closed.
(Just remember that you still need air to breathe!) Prevent any kind of cold
air from suddenly touching the 3D print.
• Adjust the cooling: This can be tricky, as you still need to cool the filament for
better bridging, less stringing, and to allow the melted plastic to return to a
solid fast enough to build an accurate geometry. But turning off or lowering
the speed of the cooling fans that are directed at the 3D print, at least for the
first few layers, may help to even out temperatures enough to keep your
model flat on the build plate.

As we mentioned, improving the adhesion of your bottom layer on the print bed can
be enough to prevent the corners from lifting. This usually involves coating the bed
in a layer of something sticky before starting the print.

With any adhesive, it’s best to do a test print of a small part to make sure it’s not
working too well. You don’t want it to be so stuck that you damage the part (or even
your bed) when you remove it!
• Use hair spray: This helps to establish a good grip for most types of filaments.
You can also use a specially-formulated 3D printing bed spray like 3DLac.
• Use a PVA glue stick: A plain old glue stick is another popular option. There
are also specific bed adhesion products, like Magigoo 3D Printer Bed
Adhesion. This should help PLA and many other filaments stick to the build
plate. Whatever you choose, you should only need a thin, even layer on your
build plate.