Neosanding postprocessing for improving surface roughness of extrusion-based 3D printing of PLA parts: a comparative analysis of stylus profilometer and confocal profilometry methods

Abstract

Extrusion-based 3D printing (E3DP) is a popular additive manufacturing technique known for its versatility in creating prototypes and functional parts. However, achieving high surface quality has posed challenges regarding accuracy and finish. To address this issue, this study aims to enhance the surface quality of E3DP components fabricated by the fused filament fabrication (FFF) method and polylactic acid (PLA) material by applying neosanding postprocessing. The research investigates the impact of key neosanding process factors on surface roughness, namely neosanding spacing, neosanding speed, and flow rate. To ensure a comprehensive evaluation, each factor is examined at four levels, covering a wide range of values relevant to the neosanding process. Surface roughness is quantified using the average roughness parameter (Ra) and measured using both stylus profilometer and confocal profilometry methods. The results highlight a substantial decrease in surface roughness achieved through the neosanding method. At default factor levels of the neosanding method, the stylus profilometer method achieves an impressive 83% reduction in surface roughness, while the confocal profilometry method achieves an 80% reduction. Among the neosanding process factors, neosanding spacing significantly influences surface roughness values. Understanding and optimizing this factor is crucial for achieving desired surface quality in FFF-produced PLA parts. This study makes a valuable contribution to the field by optimizing surface roughness in FFF-produced PLA parts through neosanding postprocessing. By exploring the influence of neosanding tool factors and comparing measurement methods, manufacturers can enhance the surface quality of FFF-manufactured parts, paving the way for broader applications across various industries.