Abstract
Fused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased usage of polymeric matrix composites in many fields ranging from automotive to aerospace. The molds used to manufacture these components are made with different technologies, depending on the number of pieces to be made. Usually, they are fiberglass molds with a thin layer of gelcoat to lower the surface roughness and obtain a smooth final surface of the component. Alternatively, they are made from metal, thus making a single carbon fiber prototype very expensive due to the mold build. Making the mold using FDM technology can be a smart solution to reduce costs, but due to the layer deposition process, the roughness is quite high. The surface can be improved by reducing the layer height, but it is still not possible to reach the same degree of surface finish of metallic or gelcoat molds without the use of fillers. Thermoplastic polymers, also used in the FDM process, are generally soluble in specific solvents. This aspect can be exploited to perform chemical smoothing of the external surface of a component. The combination of FDM and chemical smoothing can be a solution to produce low-cost molds with a very good surface finish.
Highlights
The Fused Deposition Modeling (FDM) process was first patented by Stratasys in the 1990s to build a threedimensional plastic object without the use of a mold
A further advantage is that this softening usually occurs well below the glass Transition Temperature (Tg) and the overall component integrity is maintained. This process can be used to smooth the surface of thermoplastic components [22]. This is superfluous for parts made with injection molding as little surface roughness could be achieved, but instead it could become a process to improve the surface characteristics of a component made by FDM [23]
In order to evaluate the reproducibility of this process, two molds with the same gcode were printed
Summary
The FDM process was first patented by Stratasys in the 1990s to build a threedimensional plastic object without the use of a mold. The parts are produced layer by layer through the extrusion of thermoplastic filaments usually wound in spools [1] This is the most popular additive manufacturing technique nowadays as it offers a wide range of thermoplastic material choices from common PLA [2] up to engineering-grade materials such as Nylons [3]. Even though the Additive Manufacturing (AM) processes are challenged because of their low productivity, inferior surface quality, dimensional instability, and the internal anisotropy that decreases the mechanical properties of the products [6] This process has shown suitable to produce end-use parts and for small series production [7,8]
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