Investigations on post-processing of 3D printed thermoplastic polyurethane (TPU) surface

Abstract The reduction of product development cycle time is a major concern in industries to remain competitive in the marketplace. Among various manufacturing technologies, 3D printing technology or also known as additive manufacturing (AM), has shown excellent potential to reduce both the cycle time and cost of the product due to its lower consumption of energy and material usage compared to conventional manufacturing. Fused deposition modeling (FDM) is one of the most popular additive manufacturing technologies for various engineering applications which has the ability to build functional parts having complex geometrical shapes in reasonable build time and can use less expensive equipment and cheaper material. However, the quality of parts produced by FDM has some challenges such as poor surface quality. The focus of this study is improving the surface quality produced by Fused Deposition Modeling. The investigations include 3D printing study samples with optimum parameter settings and post-processing the sample’s surfaces by laser ablation. Taguchi’s design of the experiment is employed to identify the optimum settings of laser ablation the FDM surfaces. Laser power, laser speed and pulse per inch (PPI) are the laser settings considered in the study. Characterization of the samples are done using Dino-lite USB camera images and GFM Mikro-CAD fringe projection microscope is used to measure the surface roughness of the samples. Areal surface parameters are used to characterize and compare the surfaces of as printed and laser ablated. It is observed that the effect of laser ablation varies with respect to surfaces printed at different angles and laser-ablated with different settings. The surface roughness of laser-ablated surfaces is found to be lower than as-printed FDM surfaces