Computer Numerical Controlled Grinding and Physical Vapor Deposition for Fused Deposition Modelled Workpieces

Abstract

The use of additive manufacturing (AM) enables companies to directly produce complex end‐use parts. Fused deposition modelling (FDM) is an AM technology based on an extrusion process of fabricating parts. This layer‐by‐layer method results in a poor surface finish, and as a result, manual finishing is often required, which consequentially reduces the definition of the geometrical features. This research proposes a novel way of achieving high surface finishing by using additive and finishing processes, followed by a physical vapor deposition (PVD) coating. Two test pieces were produced, the first one was subjected to computer numerical controlled (CNC) mechanical grinding with appropriate grades of grindstones; the second one was subjected to microsandblasting to remove excess material and the stair‐stepping effect. Both test pieces were then subjected to a PVD coating process to provide a metal thin film. To benchmark the test pieces, the authors used a coordinate measure machine for dimensions and a roughness meter to verify the effectiveness of this postprocessing approach.