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<p>Fused Deposition Modeling (FDM) enables the fabrication of polymer components with complex geometries; however, poor surface finish and anisotropy limit their functional use. Existing post-processing methods often lack scalability or effectiveness. This study investigates three surface treatment techniques spray painting, acetone dipping, and copper sputtering—for improving the surface morphology of acrylonitrile butadiene styrene (ABS) parts produced by FDM. Samples were fabricated at a layer thickness of 0.254&#xa0;mm and a nozzle temperature of 300&#xa0;°C, and were subsequently characterized using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and image-based surface analysis. The results demonstrate that spray painting provided the most significant enhancement, reducing surface roughness from ~ 22&#xa0;μm to 6.5&#xa0;μm and increasing hardness by 19%. Acetone dipping achieved partial surface smoothing but compromised dimensional accuracy, while copper sputtering produced uneven coatings because of restricted deposition uniformity. The findings highlight that spray painting offers a low-cost, practical, and scalable post-processing technique for improving the functional performance of FDM-produced ABS parts, making them more suitable for applications in prototyping and tooling.</p>

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Morphological analysis of FDM parts subjected to surface treatment

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年10月24日

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  • Sunil Gaekwad,
  • Athreya V. Vikram,
  • Chandra N. Sharath,
  • B. C. Anupama

摘要

Fused Deposition Modeling (FDM) enables the fabrication of polymer components with complex geometries; however, poor surface finish and anisotropy limit their functional use. Existing post-processing methods often lack scalability or effectiveness. This study investigates three surface treatment techniques spray painting, acetone dipping, and copper sputtering—for improving the surface morphology of acrylonitrile butadiene styrene (ABS) parts produced by FDM. Samples were fabricated at a layer thickness of 0.254 mm and a nozzle temperature of 300 °C, and were subsequently characterized using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and image-based surface analysis. The results demonstrate that spray painting provided the most significant enhancement, reducing surface roughness from ~ 22 μm to 6.5 μm and increasing hardness by 19%. Acetone dipping achieved partial surface smoothing but compromised dimensional accuracy, while copper sputtering produced uneven coatings because of restricted deposition uniformity. The findings highlight that spray painting offers a low-cost, practical, and scalable post-processing technique for improving the functional performance of FDM-produced ABS parts, making them more suitable for applications in prototyping and tooling.