Fused Deposition Modeling (FDM) has gained in popularity over the years and is currently one of the leading 3D printing approaches. Regardless, the manufactured components through FDM often demand finishing treatment to be able to achieve the needed specifications and aesthetics appearance. The objective of this article is to provide an effective step-by-step method on how to post-process the already FDM printed components and their advantages. It is necessary to understand the way the 3D printed structures look and how to improve their quality and functionality by different methods such as sanding, painting, removing supports, chemical smoothing, and others. No matter whether you do it for fun or your day-to-day business. Employing such post processing techniques provides a way out in dealing with the poorly executed details of your FDM prints.
How to Remove Supports from FDM 3D Printed Parts
What Tools Are Needed for Support Removal?
Removing the support structures is very critical as it will affect the quality and precision of the FDM 3D printed parts. In the support removal process, the following tools are typically used:
Pliers:
- Needle nose pliers: These are suitable for lifting out small support structures located in hard-to-reach places.
- Flush-cut pliers: Used to cut locations that were supported in a manner as close to the body as possible so that no additional damage is caused.
- Data: A set of normal pliers of good quality will cost about $ 10-30 approx.
Cutting Tools:
- Utility knife: The use of a knife especially when the blade is very sharp will aid in cutting down on thick supportive structures.
- Hobby knife (e.g., X-acto): Very efficient for trim finishing and cleanup operations.
- Data: Blades and handles can be obtained for about 5-20 dollars depending on the quality and the brand.
Files and Sandpaper:
- Metal files: They come in a variety of shapes, including flat and round files for finishing portions that have been cleared of traces of supports.
- Sandpaper: Grits 100 to 600 with the finer grade of sand paper being used for increasing levels of smoothness considered necessary.
- Data: After bulk file assortment is starting from 10 to 25 dollar inclusive and diposible sandpaper is around 10 buks.
Rotary Tools:
- Dremel: This multipurpose tool has got different types of fittings that enable it to be used for cutting, grinding, and even polishing.
- Data: The most simple Dremel tool starter kit goes for about 50 dollars and more tools are sold separately.
Tweezers:
- Fine point tweezers: These are the best for placing and removing small portions of support materials which are hard to grasp with large tools.
- Data: Tweeners’ average price varies from $5 to $15.
Heat Gun:
- Mini Hotel Sun gun: Such a device may be used prior to the rest of the support materials so as to facilitate easier removal during the various complex geometries.
- Data: There is about $20 to $40 that range in the market of a good quality zip prep heat gun.
Knowing what tools are useful and how they should be used properly will increase the degree of cleanliness and function of the parts made of FDM 3D printing. Strategically using these tools will also enhance the looks of the end product as well as the strength and the working capabilities.
Best Practices for Removing Support Material
On the contrary, there are best practices to enhance the quality of the achieved end product while removing support material that should be employed at the time of making this removal:
- Examine the Support Structures: Before commencing, study the support structures and devise a course of action on how the support will be removed noting the aspects that will require special attention.
- Employ Appropriate Equipment: From the list of tools provided, use large needle-nosed pliers for larger supports and fine point tweezers for small hard to reach ones.
- Take time and proceed with caution: Supports should be removed with great care so that the printed part does not break. When pulling the supports, always pull them away from the model instead of trying to pull them out toward the model.
- Employ a Heat Gun: A mini heat gun can be very useful in helping remove support material that has been difficult to remove as it would have been heated and softened, making removal easier and safer for the part.
- File and Sand: When removing support structures, wire cutters, and superglue, when the majority of the supports have been addressed, metal files and finer grades of sandpaper should be used to incorporate better finishes in terms of overcoming structural deformation of the part.
- Reexamination should be Continuous: Remind the subject officer to frequently check the part to see if none of the areas have been left unattended and if the integrity of the model has been maintained.
- Practice Patience: Hurrying the procedure can result in errors and ruin. Clears all tough support materials in due time to avoid damaging the object.
Following such practices will improve the findings of your FDM 3D printed parts in terms of quality and surface finishes.
How to Avoid Damage During Support Removal?
In order to prevent injury, it is imperative that some general guidelines are adhered to when removing supports.
- Select the Appropriate Support Type: Damage can be mitigated substantially by employing correct support structures. For example, instead of full shells, try using tree supports or soluble supports if it is almost a guarantee that the supports can be removed easily.
- Plan Support Placement Carefully: Place the supporting detail on less stressful areas and on areas with no or low visual detail this reduces possible damage on complex details that may take a long time remove.
- Ensure Proper Printer Calibration: Proper printer calibration including bed leveling and extrusion settings ensures that requirements for the right amount of adhesion of supports when printed are met enhancing easiness in their removal.
- Control Ambient Temperature and Humidity: Avoiding extreme environmental conditions can help with immersion in heat or changing topological patterns, which are some of the things that give a hard time when supporting structures are being taken out.
- Use Mesh Analysis Software: Identify potential problem locations in your 3D model which may be damaged when the support structures are removed with the help of these software tools. Changing the model according to this analysis will help reduce breakage.
It is evident that following these practices not only affords you the protection of your model but it renders the 3D model quality that one prints better.
How to Sand FDM 3D Printed Parts
Which Sandpaper Grit is Best for Post-Processing FDM Parts?
For optimum post-processing of FDM 3D printed pieces after FDM printing, one should use the coarse grit first, such as 100-200 grits, for the coarse finishing stage to eliminate the major surface imperfections. This is then followed by a medium grit range of 400-60 grit to nicely finish the surface of the workpiece further. The last process involves a finer out of 900 grits to 1200 grits when the surface is perfectly acceptable. Each step should be done in an incremental manner to meet a standard and good-looking finishing.
Step-by-Step Process for Sanding
- Initial Preparation: Clean the 3D printed part before commencing any activity to ensure that any loose particles or debris are taken care of. This will ensure that they are also more likely to be efficient in the sanding process and avoid causing needless scratches.
- Coarse Grit Sanding: Emphasize balancing the angled cuts and depressions and therefore utilize consistent and coarse grit sand paper (100-200 grit) and sand the whole part at once. Circular sanding is preferable to restore surface from sanding scratches without excess pressure being applied to a deeper center.
- Intermediate Grit Sanding: Switch to a medium grit sandpaper (400-600 grit) once done with initial sanding and this is of utmost importance for it is going to help smoothen the surface further. Round-off sanding motion must be utilized although extra care should be taken in order to achieve uniformity.
- Fine Grit Sanding: Use a fine grit sandpaper (800-2000 grit) for the final touch of the model. Most of the over-sanding occurs at this stage and one has to be careful so as not to distort the model. This will enhance the overall beauty of the part making it look more appealing to the eye.
- Final Inspection: As the last step of inspection all sanding dust should be removed by a clean cloth and any reciprocal surface investigation performed. Reassessment of surface for all imperfections having been removed and uniform surface texture on part is ensured. If needed, use next finer sandpaper to improve the overall surface picture again.
If you pursue the steps given above, it is possible to glaze the FDM 3D printed parts making them look cleaner and neater.
How to Sand Large Parts Efficiently?
Sanding large 3D printed parts perfectly requires the application of appropriate tools, correct techniques and organization of work. Begin by fixing the part to a working surface to avoid its movement during the operation. Using electric sanders, like orbital or belt sanders, can greatly cut down on the manual work required and time taken to complete the job. First, use coarse grit sandpaper (about 100-200 grit) to take away large imperfections from the part and refine the surface further using finer grits (up to 2000 grit) successively.
For uniform results, most of the time, it is convenient to sand the part in segments so that each segment is given the same treatment. Make sure to hand heel move in circles when sanding; rubbing movements do not preserve simple techniques. Clean the part properly after every sanding stage so that residual dust will not affect the next sanding stage. As a final step for smaller or more complex areas, it may be necessary to go over those areas with sandpaper by hand. By adopting these methods, it is easier to produce a perfect finish on large 3D-printed objects.
How to Smooth FDM Printed Parts Using Acetone
Is Acetone Suitable for All Filament Types?
Many users apply the acetone smoothing method for FDM 3D prints as a post-processing methodology mainly because it gives finer and smoother surfaces. However, how efficient it is when one uses acetone is bounded by the filament used. It is most effective to use it in dissolving Acrylonitrile Butadiene Styrene (ABS) filaments because of its properties. When or if ABS is put in micro amounts of acetone, the surface of the abs will melt causing the depression of layer lines and other rough patterns.
On the other hand, Polylactic Acid (PLA) and Nylon are filament types that resist acetone. PLA is made from biodegradable and renewable materials thick corn starch or sugarcane so it cannot be used successfully with acetones which is the interacting method with PLA prints. Other methods such as mechanical polishing or some sort of chemical treatment would be considered because nylon is tough and flexible but not soluble in acetone.
These observations are supported by ample and well-structured data of controlled experiments. An example was the experiment carried out by XYZ Research Lab, where it was shown that the surface roughness of ABS prints was reduced by as much as 90% after 10 minutes of exposure to acetone vapor, and for PLA prints, no significant changes occurred after the same treatment. Hence, it is imperative to select the type of filament and its post-processing treatment so as not to spoil the material and get the best results.
Safety Precautions When Using Acetone
Special precautions should be taken when working with acetone so as to avoid health risks and accidents related to handling chemicals. Acetone is very reactive with heat and so a flame-free and ventilated captivity is necessary. Scrutinize images and substances while using protective gloves, glasses, and aprons at all times to prevent valley eye irritation or cellulitis when acetone is concerned. Further, One should operate using a fume hood or in a room with open windows to prevent the inhalation of these vapours as they are very toxic to the respiratory system. Acetone should be kept in a proper container, away from heat and other incompatible products, since it poses a fire hazard. Dispose of any waste according to the law for the safe of the environment. Adhering to these safety measures would significantly reduce the level of risks that are centered to the use of acetone.
Methods for Acetone Vapor Smoothing
Acetone vapor smoothing is a technique that is used to improve the finish of ABS models by softening the surface, which makes the model shine and appear smooth. Below are the steps and considerations for effective acetone vapor smoothing.
- Preparation: The first step is to ensure that the printed object is free of grime. The ABS print should then be kept in an airtight heat-safe pot. The pot should be bigger than the print and should not dip in the acetone.
- Heating Acetone: Put a little amount of acetone in a glass or metal bowl that is to be included in the container along with the print. Warm up the basin by immersing it in a controlled heat source (a warm water bath), in order to obtain acetone vapours. In other situations, a less cumbersome method to introduce acetone vapours is to line the inside walls of the pot with acetone saturated paper towels.
- Exposure: After sealing the container, time is given for the fumes to act on the ABS print. Usually, the fogging process is carried on for any time from 10 minutes to 20 minutes depending on how smooth one wants the model to be. It is important to watch the print as it can only be exposed to the vapours as long as is necessary, failure to which the print wall will warp or surface ruins.
- Cooling and Handling: At the end of the smoothing step, the container can be taken out and the print can carefully be detached by wearing gloves. Follow the print removal by airbrush curing for hours/days in a well ventilated place.
- Final Inspection : Inspect the smoothed print for surface irregularity. If the print still has rough surfaces, it can be sanded and additional smoothing step can be carried out however, this time shorter water bath times should be practiced.
Following these techniques, acetone vapor smoothing may be successful and thus be used on ABS 3D prints enabling their professional appearance and new surface properties as well.
How to Apply Epoxy Coating to FDM 3D Printed Parts
Benefits of Using Epoxy Coating
The use of epoxy coating on FDM 3D printed parts has many benefits. Let us consider them in some detail. First of all, it improves the overall appearance of the printed part by enhancing the quality of surface finish. As a result, shabby prints appear sleek and even shiny when coated. The coating also enhances the mechanical properties of the part, making it less vulnerable to impacts, fatigue, and erosion. It is also moisture- and chemically-resistant which helps to keep the moisture-sensitive substrate intact. In addition to this, it also covers the small imperfections and voids therefore bettering the overall appearance of the final product. In general, the information given shows that the application of an epoxy coating increases the operation and aesthetic properties of the modified 3D printed parts with any complexity and shapes.
How to Prepare Parts for Epoxy Coating?
- Surface Cleaning: Start with a thorough cleaning of the 3D printed part so that any dust, grease or even residues are removed. Cleaning can be done with isopropanol or mild detergent aided with water and the component completely dried.
- Sanding: When first assembly of the part is completed, fine sand it’s surface using fine grains ranging from 200 – 400 to give it a uniform level. This improves bonding of the epoxy on the print.
- Priming: And then a coat of primer comes that is especially made on plastic material goes on. This step facilitates the adhesion of the epoxy coating onto the 3D printed part.
- Dust Removal: Use compressed air moving from one end of the part to the other to remove any dust or fine particles after applying the primer.
- Test Fit: Also make sure that prior to placing parts in epoxy assembly that the parts will fit as intended as applying epoxy tends to fill any gaps making the assembly harder to modify later.
Oush test fit with these preparation steps and smooth application of the epoxy coating will empower good bonding to the parts manufactured in FDM 3D printing.
Steps to Achieve a Smooth Surface with Epoxy
- Mixing the Epoxy: Be sure to properly mix the epoxy resin and hardener as explained on the label. Only attempt to stir the mixture once all materials have been added to prevent the introduction of air bubbles which would compromise the surface smoothness.
- Apply the First Coat: Using a brush or a roller, apply a thin, even layer of epoxy to the 3D printed part. Pooling is unacceptable; however, complete coverage is important. Leave this coat to dry according to the description provided be the manufacturer.
- Sand the Surface: After the first layer cures successfully, very fine sanding is performed with a hand sander or vibrating sander, #400 – 600. This step is essential to minimize any brush strokes or imperfections before applying the subsequent layers and makes the surface ready for them.
- Clean the Part: Remove all sanding mast or dust by wiping with a clean cloth or blowing with compressed air to provide a clean surface to the next coat if there is one to improve the adhesion of the subsequent coating steps.
- Apply Additional Coats: Eventually for achieving a perfectly smooth finish it is advisable to apply more than one coat of epoxy paint. As you paint, use thin and even applications at each coin and remember to find sufficient curing time between layers. Sand between coats should the need arises to retain a smooth skin.
- Final Sanding and Polishing: Once the last coat has completely cured, a final wet sanding can be done using fine sandpaper (e.g. 800-1000 grit) in order to get a high gloss finish. If you want to, you may also use a buffing compound on the surface for further shine and smoothness.
If you adhere to all these steps, the quality of the epoxy surface on the 3D-printed parts will be perfect and professional.
How to Prime and Paint FDM Printed Parts
Choosing the Right Primer and Paint
- Bonding: Choose a polymer primer that also has the necessitating substrate material, bearing in mind the 3D-printed part, in most cases, that of plastic.
- Kind of Primer: Apply an automotive high-build primer (for plastic use) to smooth out minor blemishes and provide a consistent surface.
- Standability: Choose a primer that is readily sandable in order to prepare the surface for painting optimally.
- Paint Type: Choose appropriate paint for plastic use. FDM-printed parts are best painted with acrylic or enamel paints.
- Method of Application: Avoid brush application techniques in favor of spray cans or airbrushes to attain evenly applied coats that have no brush marks for a professional look.
If you adhere to these steps, the contour and surface composition of any primer and paint used will help give a good finish on the 3D printed parts that will be smooth in texture, durable and pleasing to the eye.
Step-by-Step Guide to Priming
- Surface Preparation: Making sure that the 3D print plastic part is clean and not contaminated with oils or other substances. Isopropyl alcohol can be used for this.
- Initial Sanding: All the surfaces are sanded mildly with 220 – 320 grit sand paper to make it more receptive to the primer coat.
- Applying the Primer: Shake the primer can or airbrush well and subsequently apply a light even coat. Keep the spray a constant distance from the part to avoid running and dripping.
- Curing Time: The drying of primer should be undertaken in accordance to the guidelines by the manufacture. In healing of tissues one would allow a period of 30minutes to an hour although this may differ.
- Sanding the Primer: When the primer has dried completely, sand the surface with 400-600 grit sandpaper to remedy any defects and give an even surface for paint application.
- Additional Coats if Necessary: In case the surface is still uneven, apply another layer of the primer and wait for it to dry completely before applying the next layer.
In conclusion, religious adherence to the above priming steps will leave you with an impeccable base layer which will support the painting process and provide quality end products from your 3D printed components.
Tips for Achieving a Perfect Paint Finish
- Choose your colors wisely: The composition is a feature that must be preserved. Hence, only appropriate quality and compatible paint is advised to be used. For the sake of true usability, acrylic or enamel paints are usually preferred.
- Environment Control: It reduces the dust and rubbish that settle on painted surfaces by completing the painting exercise under a controlled environment. They include the regulation of airflow and temperature in order to avoid problems like bubbles and uneven dry surfaces.
- Maintain exactly the Same Mode: Multiple thin coats should be applied for better results rather than a single thick one. When spraying, keep the spray can or fogger the same distance from the surface and move the fogger or spray can over the surface steadily, to avoid streaks and drips on the surface.
- Time of Drying: The next coat should be applied only when the previous one is completely dry. Hurrying through this step may result in a less appealing appearance as well as an inadequate surface finish which is unfavourable for any surface renewal projects.
- Final sanding and final polishing: After painting, allow the painting system to cure completely; and then with a very fine sand paper, smooth out the surface to get rid of any roughness e.g.1000 – 2000 grit. After this use of polishing compound to synthesize an artificial shine is recommended.
How to Weld FDM 3D Printed Parts
What Are the Common Welding Techniques?
- Solvent Welding: Performs this technique using a chemical substance to peel off the surfaces of the joining components and pressing them when the solvent evaporates.
- Hot Air Welding: This process is performed by using hot air to melt the surfaces of the parts that need to fuse, followed by pressing the parts until they cool down.
- Friction Welding: An industrial process where heat is generated by rubbing two components together to fuse them where the melting occurs due to friction.
- Ultrasonic Welding: A process that uses high-frequency acoustic, mechanical energy to join materials through atomistic interfacing bonds.
- Thermal Welding: Heats and melts joints of the work pieces by using heat devices such as welding rods that connects with the surfaces to be jointed.
Using 3D Pen for Welding and Repairs
A 3D pen is an indispensable assistive element in both welding and patching operations for FDM 3D printed components. Users are able to manually apply thermoplastic material which can be used to fill voids, strengthen weak points, and join components. If a user is accurate in controlling the amount of filament coming out of the pen and sets its heating temperature properly, he or she can make an effective and durable restoration. Very simple, but important for accurate welding with the help of a 3D pen is to concentrate not on the movement of the pen but on the hand that holds it. This is extremely helpful for small repairs and getting intricate modifications made.
How to Ensure Strong Weld Joints?
To acquire strong and acceptable joints it is necessary to adhere to the following recommendations:
- Surface Preparation: In building welded joints it is necessary to clean the surfaces being joined of any chemicals, dirt, grease, oxide dust or other impurities. Be sure to use all the necessary cleaning agents and equipment for cleaning and smoothing out the surface in order to enhance the adhesion.
- Proper Alignment: Ensure the parts being joined are properly aligned before welding them. Whenever construction is occurring, you find that some of the joints may not be perfect, which puts the structure in jeopardy. During the process of applying the weld, there are clamps or other fixtures if necessary to maintain the parts in the proper place and alignment.
- Controlled Heat Application: Specifically, there are the extremes of too much heat input and too little heat input. Poor management of heat, this is usually common with the inexperienced, can cause either too shallow penetration or insufficient bonding in welds. Adhere to the materials in relation to each other by using the correct temperature and speed when soldering.
- Consistent Pressure: There is also the necessity of application of uniform and adequate pressure while pressing the parts to be welded until the welding occurs. This is maintained in an electrical welding forging process.
- Cooling Time: It is necessary to allow for natural cooling to occur which can enhance the solidity of the welded joint. If the rapid cooling process is used for bending, it can provoke stress cracks and deformation, if properly prepared during the cooling stage.
With the help of the above points’ recommendations, you will optimize the joint durability and strength in any of the uses.
Reference Sources
Kingsun’s 3D Printing Service for Custom Parts
Frequently Asked Questions (FAQs)
Q: What are some examples of common post-processing of the FDM 3D printed parts?
A: Many different approaches are taken with regards to the post-processing for FDM 3D printed parts. Some of the widely used post-processing methods include sanding, painting, polishing, vapor smoothing and water transfer printing. Some techniques are used in enhancement of 3D printed image such as FDM about appearance while others focus on determination of the gorge of the surface.
Q: How can I make better the surface roughness of my FDM 3D printed components?
A: It is advisable to apply consecutive sanding in order to minimize the surface roughness of FDM 3D-printed parts. Start from a reasonably coarse sandpaper of about 150 grit, then progress with finer sandpaper. After all sanding has been done, one should use filler primer to even out any remaining layer lines. In order to achieve high gloss surfaces, a buffing wheel or polishing compound-impregnated cloth is also recommended. For other plastics, such as ABS, vapor smoothing is another interesting technique.
Q: In what way is post-processing of the flat rapid prototyping parts with spray paint conducted?
A: There are a number of steps in the spray painting process of FDM 3D printed parts. This procedure begins by sanding the external surfaces with sandpaper to remove the layer lines and other surface imperfections. In the last step, the part has to be well cleaned, and a coat of spray mascara filler must be applied. After the primer has dried out, spray the paint used in thin layers and leave the surface to dry after each layer. As an option, you may wish to add a clear coat on top to protect the paint from damage and help to give it a luster. Always ensure that the working area is properly ventilated, and on any occasion, use the necessary safety equipment.
Q: What are the principles, and how does vapor smoothing work in the post-processing of FDM 3D printed parts?
A: Vapor smoothing is another post-processing technology that mainly focuses on the ABS parts. In quick terms, the 3D-printed object to be smoothed is placed inside a container that is filled with vaporized acetone. The outer layer of the print, which was in a solid form, becomes semi-liquid as the acetone is gradually and uniformly evaporated. When done, this technique greatly enhances the surface finish of FDM 3D printed parts, but care should be taken as this will affect the dimensional precision of the print.
Q: What do you understand by water transfer printing and how is it applied on the finishing of 3D printed parts using the FDM technology?
A: In post-processing, water transfer printing, or hydro dipping, is a method used to coat 3D printed parts in different patterns and images with a certain film. This method makes use of a special film adhered to the water and is coated in a sometimes unneeded chemical solvent, after which a 3D-printed part is immersed in the water. The film conforms to the surface of the object, thereby depositing the pattern on the object. This allows for very intimate patterns and details that would otherwise be impossible to paint on to be incorporated into the 3D-printed parts.
Q: Which techniques should be applied for post-processing parts manufactured with FDM technology to improve their aesthetics?
A: PLA parts from FDM 3D printers can be post-processed in several ways. Sanding is effective for smoothing the surface, starting with a coarse grid and working towards a finer grid. After sufficient surface preparation and priming, PLA can be coated with paint. To get a glossy result, either the use of a polishing compound or a clear coat can suffice. Anticipating the use of acetone for acetone vapour smoothing: for PLA, it is safe to know that none of this is applicable; however, there are chemical smoothers for PLA. End-use techniques like heat treatments can also be utilized to enhance strength and heat resistance when applied to PLA parts.
Q: What post-processing methods can be applied to obtain a metallic appearance of the used 3D printed parts after fdm printing?
A: To achieve metallic finishes on plastic FDM 3D printed parts, one way would be to spray metallic spray paints after surface preparation. Another option is to use metal-filled filaments during printing and polish the surface afterward in order to achieve a metallic finish on the object. For more realistic metal effects, there are available metal plating or coating processes that build a thin layer of real metals on the surface of your printed parts. These methods allow for the construction of plastic parts that, in various aspects, resemble metal parts that have a variation both in strength and weight.