Vapor smoothing process for surface finishing of FDM replicas

Abstract

This paper explores the possibilities of utilizing acetone as an alternative solvent for finishing of acrylonitrile butadiene styrene (ABS) parts in controlled environment. The experiments were conducted on replicas of hip implant master pattern prepared through fused deposition modelling (FDM) to highlight its applicability in manufacturing of biomedical implant via rapid casting (RC) route. The series of experiments were conducted to evaluate impact of smoothing duration and repetition of smoothing cycles on surface finish and stability of ABS replicas. It was experienced that increase in exposure of acetone vapors manifested better surface finish but, beyond critical limit, the adverse effects was appeared leading to distortion of the upper surface. The excessive reflow of upper layers of ABS parts reduced weight and disturbed the geometry of hip replicas. The upper and lower limits of smoothing duration to safeguard the surface integrity and profile of hip replicas have been successfully chalked out. The acetone has been recommended to be used as solvent for finishing of ABS replicas which can revolutionize the production of biomedical implants through RC.