Unit 5: Post Processing of AM Parts and Future Directions of AM

Most AM processes require post-processing after part building to prepare the part for its
intended use. Depending upon the AM technique, the reason for post processing varies. For
purposes of simplicity, we will focus on post processing techniques which are used to enhance
components or overcome AM limitations. These include: 1. Support Material Removal 2.
Surface Texture Improvements 3. Accuracy Improvements 4. Aesthetic Improvements 5.
Preparation for use as a Pattern 6. Property Enhancements using Non-Thermal Techniques 7.
Property Enhancements using Thermal Techniques.

Support Material Removal

The most common type of post-processing in AM is support removal. Support material can
be broadly classified into two categories:

(a) material which surrounds the part as a naturally-occurring by-product of the build process
(natural supports),

(b) rigid structures which are designed and built to support, restrain or attach the part being
built to a build platform (synthetic supports).

Natural Support Post-Processing

In processes where the part being built is fully encapsulated in the build material, the part
must be removed from the surrounding material prior to its use. Processes which provide
natural supports are primarily powder-based and sheet-based pro cesses. Specifically, all
powder bed fusion (PBF) and binder printing processes require removal of the part from the
loose powder surrounding the part; and bond then-form sheet metal lamination processes
require removal of the encapsulating sheet material.

In PBF processes, after the part is built it is typically necessary to allow the part to go through
a cool-down stage. The part should remain embedded inside the powder to minimize part
distortion due to non-uniform cooling. The cool-down time is dependent on the build material
and the size of the part(s). Once cool-down is complete, there are several methods used to
remove the part(s) from the surrounding loose powder. Typically, the entire build (made up
of loose powder and fused parts) is removed from the machine as a block and transported to
a “breakout” station where the parts are removed manually from the surrounding powdered
material. Brushes, compressed air, and light bead blasting are commonly used to remove
loosely adhered powder; whereas, wood-working tools and dental cleaning tools are
commonly used to remove powders which have sintered to the surface or powder entrapped
in small channels or features. Internal cavities and hollow spaces can be difficult to clean and
may require significant post-processing time.

With the exception of an extended cool-down time, natural support removal techniques for
binder printing processes are identical to those used for PBF. In most cases, parts made using
binder printing are brittle out of the machine. Thus, until the parts have been strengthened
by infiltration the parts must be handled with care. This is also true for PBF materials that
require post-infiltration, such as some elastomeric materials, polystyrene materials for
investment casting, and metal and ceramic green parts.

Bond-then-form sheet lamination processes, such as laminated object manufacturing, also

require natural support material removal prior to use. If complex geometries with
overhanging features, internal cavities, channels or fine features are used, the support
removal may be tedious and time-consuming. If cavities or channels are created, it is often
necessary to delaminate the model at a specific z-height in order to gain access to de-cube
the internal feature; and then re-glue it after removing excess support materials.

Synthetic Support Removal

Processes which do not naturally support parts require synthetic supports for overhanging
features. In some cases, such as when using PBF techniques for metals, synthetic supports are
also required to resist distortion. Synthetic supports can be made from the build material or
from a secondary material. The development of secondary support materials was a key step
in simplifying the removal of synthetic supports as these materials are either weaker, soluble
in a liquid solution, or melt at a lower temperature than the build material.

The orientation of a part with respect to the primary build axis significantly affects support
generation and removal. If a thin part is laid flat, for instance, the amount of support material
consumed may significantly exceed the amount of build material.
The orientation of supports also affects the surface finish of the part, as support removal
typically leaves “witness marks” (small bumps or divots) where the supports were attached.
Additionally, the use of supports in regions of small features may lead to these features being
broken when the supports are removed. Thus, orientation and location of supports is a key
factor for many processes to achieve desirable finished part characteristics.

Supports Made from the Build Material

All extrusion, direct printing and photopolymer processes require supports for overhanging
structures and to connect the part to the build platform. Since these processes are used
primarily for polymer parts, the low strength of the supports allows them to be removed
manually. These types of supports are also commonly referred to as breakaway supports. The
removal of supports from downward-facing features leaves witness marks where the
supports were attached. As a result, these surfaces may require subsequent sanding and
polishing.

PBF and beam deposition processes for metals and ceramics also typically require support
materials. An example dental framework, oriented so that support removal does not mar the
critical surfaces. For these processes the metal supports are often too strong to be removed
by hand; and thus the use of milling, band-saws, cut-off blades, wire-EDM and other metal
cutting techniques are widely employed.

Supports Made from Secondary Materials

A number of secondary support materials have been developed over the years in order to
alleviate the tedious, time-consuming, labor-intensive, error-prone manual removal of
support materials. Two of the first technologies to use secondary support materials were the
Cubital layer-wise photopolymerization process and the Solids cape direct printing process.
Their use of wax support materials enabled the block of support/build material created during
processing to be placed in a warm water bath; thus melting or dissolving the wax and leaving
behind the final parts. Since that time, secondary supports have become common
commercially in FDM and direct printing processes. Secondary supports have also been
demonstrated for form-then-bond sheet metal lamination and beam deposition processes in
research environments. For polymers, the most common secondary support materials are
polymer materials which can be melted and/or dissolved in a water-based solvent. The water
can be jetted or ultrasonically vibrated to accelerate the support removal process. For metals,
the most common secondary support materials are lower melting-temperature alloys or
alloys which can be chemically dissolved in a solvent (in this case the solvent must not affect
the build material).

Postprocessing for Surface Texture Improvements

AM parts have common surface-texture features that may need to be modified for aesthetic
or performance reasons. Common surface textures are: stair-steps; powder adhesion; fill
patterns from extrusion or beam-based systems; and witness marks from support material
removal.

Stair-stepping is a fundamental issue in layered manufacturing and is difficult to overcome,

although one can choose a thin layer thickness to minimize error at the expense of build time.

Powder adhesion is also a fundamental characteristic of binder printing, PBF and powder-
based beam deposition processes. The amount of powder adhesion can be controlled, to
some degree, by changing part orientation, powder morphology and thermal control
technique.

The type of post-processing utilized for surface texture improvements is dependent upon the
desired surface finish outcome. If a matte surface finish is desired, a simple bead blasting of
the surface can help even the surface texture, remove sharp corners from stair-stepping and
give an overall matte appearance. If a smooth or polished finish is desired, then wet or dry
sanding and hand-polishing are per formed.

In many cases, it is desirable to paint the surface (e.g., with cyanoacrylate, or a sealant) prior
to sanding or polishing. Painting the surface has the dual benefit of sealing porosity and, by
viscous forces, smoothing the stair-step effect; thus making sanding and polishing easier and
more effective.

Several automated techniques have been explored for surface texture improvements. Two of
the most commonly utilized include tumbling for external features and abrasive flow
machining for, primarily, internal features. These processes have been shown to smooth
surface features nicely, but at the cost of small feature resolution, sharp corner retention and
accuracy.
Post-Processing for Aesthetics Improvements

Aesthetics improvement in additive manufacturing is essential to enhance the visual appeal

and surface finish of 3D-printed objects. Achieving better aesthetics can be crucial for
consumer products, architectural models, medical devices, and various other applications.
Here are several methods for improving the aesthetics of 3D-printed parts:

Layer Height and Resolution:

Adjust the layer height of the 3D printer. Smaller layer heights result in smoother surfaces
and finer details, enhancing the overall appearance of the printed object.

Printing Orientation:

Experiment with different printing orientations to minimize visible layer lines or to

strategically position them where they are less noticeable. Orienting parts to minimize
overhangs and support structures can also improve aesthetics.

Post-Processing:

Post-processing techniques can significantly enhance the aesthetics of 3D-printed parts.

Some common post-processing methods include:

Sanding: Sand the surface of the part to smooth out layer lines and imperfections.

Filling: Apply filler or putty to any gaps, seams, or imperfections, and then sand for a smooth
finish.

Priming: Apply a primer to prepare the surface for painting or other finishing techniques.

Painting: Use various painting techniques to add color and texture to the part.

Polishing: Polish the part using abrasive compounds or a vibratory tumbler for a glossy finish.

Support Structure Removal:

Carefully remove support structures generated during the 3D printing process to avoid leaving
rough or uneven surfaces. Consider using support structures that are easier to remove
cleanly.

Multiple Materials and Multi-Material Printing:

Utilize multi-material 3D printing to incorporate different colors or textures into your designs.
This allows for a broader range of aesthetic options.

Finishing Coatings:

Apply specialized coatings or finishes to improve aesthetics. These may include gloss or matte
finishes, clear coats, and texture coatings.

Texturing:

Add texture to the 3D-printed object by altering the 3D model or using specialized printing
techniques. Texture can be used to create unique visual effects and improve aesthetics.

Decals and Labels:

Apply decals, labels, or graphic overlays to enhance the visual appeal and add branding or
information to the 3D-printed part.

Filament Selection:

Choose 3D printing filaments that are known for producing aesthetically pleasing results, such
as filaments with a smooth surface finish or those specifically designed for visual appeal.

Custom Designs:

Customize the design of the 3D-printed object to include aesthetic features, patterns, or
branding that align with your intended aesthetics.

Lighting Effects:

Incorporate lighting effects into the design, such as LED illumination, to create unique visual
enhancements and highlight specific areas of the printed object.

Assembly and Integration:

Assemble multiple 3D-printed parts into a single assembly, ensuring that the joints are well-
designed and align correctly to improve the overall aesthetic appeal.
Non-thermal Post-processing Techniques

• Powder-based and extrusion-based processes often create porous structures. A

higher-strength material, such as cyanoacrylate (strong fast-acting adhesive), can infiltrate
porosity. Proprietary methods and materials have been developed to increase the strength,
ductility, heat deflection, flammability resistance, EMI shielding, and other properties using
infiltrates and nano-composite reinforcements.

• SLA - many photopolymers do not achieve complete polymerization

Post-Cure Apparatus: a device that floods the part with UV and visible radiation in order to
completely cure the surface

Thermal Postprocessing Techniques

• In DED (Directed Energy Deposition) & PBF (Powder Bed Fusion) [SLS/EBM] it is
primarily heat treatment to form the desired microstructures and/or to relieve residual
stresses.

• In some cases, special heat treatment methods are adopted to retain the fine-grained
microstructure while still providing stress relief and ductility enhancement.

• Before DED & PBF (directly process metals and ceramics) many techniques were
developed for creating metal and ceramic green parts using AM. These were then furnace
post-processed to achieve dense, usable metal and ceramic parts.

• Green Part: a polymer coated metallic powder, or a mixture of metallic and polymer
powders are used for part construction. The polymer binder is melted and binds the particles
together, and the metal powder remains solid. The metallic powder particles remain largely
unaffected by the heat of the laser.

• The polymer-bound green parts are subsequently furnace processed in two stages: (1)
debinding and (2) infiltration or consolidation.

• During debinding, the polymer binder is vaporized to remove it from the green part.
Typically, the temperature is also raised to the extent that a small degree of necking
(sintering) occurs between the metal particles.
• Subsequently, the remaining porosity is either filled by infiltration of a lower melting
point metal to produce a fully dense metallic part, or by further sintering and densification to
reduce the part porosity.

Postprocessing for Accuracy Improvement

Post-processing plays a crucial role in improving the accuracy, surface finish, and overall
quality of additive manufactured (AM) parts. Here are several post-processing techniques
commonly used to enhance the accuracy of AM parts

1. Surface Smoothing:

• Sanding and Polishing: Abrasive materials are used to smooth the surface of
the printed part. This is effective for reducing layer lines and creating a more
aesthetically pleasing finish.

• Chemical Smoothing: Immersing the part in specific chemicals can dissolve and
smooth the outer layer of the printed material. This is common with resin-
based 3D printing processes.

2. Support Removal:

• Supports are structures added to help stabilize overhanging features during

the printing process. Removal can be done manually, with tools, or through
water-soluble support structures that dissolve in water.

3. Abrasive Finishing:

• Sanding and Grinding: Manual or automated processes that use abrasives to

remove excess material, refine surfaces, and achieve tighter tolerances.

• Blasting: Abrasive particles are propelled at high speed onto the part's surface
to remove roughness and improve the finish.

4. Heat Treatment:

• Annealing: Heating the part to a specific temperature and then allowing it to

cool slowly can relieve internal stresses, improve material properties, and
enhance dimensional stability.
5. Machining:

• Milling, Turning, and CNC Machining: Using traditional subtractive

manufacturing processes to achieve precise dimensions, particularly for critical
features or areas where tight tolerances are required.

6. Surface Coating:

• Painting and Powder Coating: Applying coatings to enhance the part's

appearance, protect against corrosion, or provide specific functional
properties.

• Anodizing: Common for aluminum parts, this electrochemical process forms a

protective oxide layer on the surface.

7. 3D Printing-specific Post-Processing:

• Post-curing: For resin-based 3D printing, exposing the part to additional UV

light after printing to further cure the material and improve its final properties.

8. Topology Optimization:

• Software-driven Design Optimization: Using computer-aided design (CAD)

software and algorithms to optimize the part's structure, reducing material
usage and weight while maintaining or improving performance.

9. Dimensional Inspection:

• CMM (Coordinate Measuring Machine): A precision measurement device

used to verify that the dimensions of the printed part match the intended
design.

• 3D Scanning: Capturing the part's geometry in 3D to compare it against the

original design and identify any deviations.

10. Surface Coating:

• Electroplating: A process where a metal coating is deposited onto the part's

surface through electrolysis. This can provide enhanced properties such as
conductivity or corrosion resistance.
 11. Ultrasonic Finishing:

• Vibratory Finishing: The part is immersed in a vibrating container with abrasive

media and, sometimes, a finishing compound. This helps in removing burrs,
improving surface finish, and polishing the part.

The selection of specific post-processing techniques depends on factors such as the material
used, the AM process employed, the part's geometry, and the desired end-use application. A
combination of these techniques is often applied to achieve the best results in terms of
accuracy, functionality, and aesthetics.

Post-processing of AM Part for Pattern Application

When additive manufactured (AM) parts are intended for use as patterns, particularly in the
context of patternmaking for casting processes, specific post-processing operations are often
applied to achieve the necessary accuracy, surface finish, and functionality. Here are key post-
processing steps commonly performed on AM parts used as patterns:

1. Support Removal:

• As with any AM part, supports used during the printing process must be
carefully removed. This is essential for ensuring that the final pattern has the
desired geometry and is free from any unwanted structures.

2. Surface Smoothing:

• Achieving a smooth surface finish is crucial for patterns used in casting to

ensure that the molds or patterns produced from them replicate the intended
design accurately. Techniques such as sanding, polishing, or chemical
smoothing can be applied to reduce layer lines and enhance the overall surface
quality.

3. Dimensional Accuracy Check:

• Since precision is critical in patternmaking for casting, thorough dimensional

inspections using tools like coordinate measuring machines (CMM) or 3D
scanning are performed to ensure that the pattern meets the specified
tolerances and matches the intended design.
4. Geometry Optimization:

• Topology optimization or other CAD-driven design optimization processes may

be employed to refine the part's structure, ensuring that material is distributed
efficiently and that the pattern is well-suited for its casting application.

5. Hole and Feature Inspection:

• Patterns often include holes, channels, or specific features crucial for the
casting process. Inspecting and ensuring the accuracy of these features is
important to guarantee the success of the casting operation.

6. Surface Coating:

• Applying coatings or finishes can be done for both aesthetic reasons and to
enhance the functionality of the pattern. For example, coatings like release
agents may be applied to facilitate easy demolding of the cast material.

7. Supportive Structures:

• Depending on the casting process, additional supportive structures may be

added to the pattern to ensure its stability during the casting operation. These
structures should be carefully designed and integrated into the pattern.

8. Alignment and Registration Features:

• Patterns may need features that facilitate proper alignment and registration
during the casting process. These features aid in ensuring that the mold or
pattern is correctly positioned to produce an accurate cast.

9. Heat Treatment:

• Depending on the material used for 3D printing, heat treatment may be

applied to relieve internal stresses and enhance the mechanical properties of
the pattern, improving its durability and stability during casting.

10. Quality Control Documentation:

• Detailed documentation of the pattern's quality, including dimensional

measurements, material specifications, and any deviations from the design, is
 often prepared. This documentation helps in maintaining consistency in the
casting process.

11. Pattern Finishing:

• Additional manual finishing processes may be applied to fine-tune the

pattern's surface, edges, or any critical features that contribute to the quality
of the cast product.

It's important to note that the specific post-processing operations can vary depending on the
casting process (e.g., sand casting, investment casting) and the materials involved.
Customization of post-processing steps is often required to meet the unique requirements of
each casting application.

Employment opportunities in the field of Additive Manufacturing

Additive Manufacturing (AM), commonly known as 3D printing, is a rapidly growing field that
offers various employment and digital entrepreneurship opportunities. The technology
involves building objects layer by layer from digital models, offering unique advantages in
terms of customization, rapid prototyping, and cost-effective production. Here are some
opportunities in the field of Additive Manufacturing:

1. Design and Modeling:

• 3D Designers: Professionals skilled in CAD (Computer-Aided Design) software

can create digital models of products, prototypes, or parts that are suitable for
3D printing.

• Topology Optimization Specialists: Experts in optimizing designs for additive

manufacturing, ensuring efficient use of materials and improved structural
integrity.

2. Manufacturing and Production:

• 3D Printing Technicians/Operators: Skilled technicians who can set up,

operate, and maintain 3D printers, ensuring the proper printing of objects.
 • Materials Specialists: Professionals focusing on developing and optimizing
materials suitable for 3D printing, considering factors like strength, flexibility,
and cost.

• Post-Processing Experts: Individuals skilled in post-processing techniques to

refine and finish 3D-printed products.

3. Entrepreneurship Opportunities:

• 3D Printing Services: Entrepreneurs can start businesses offering 3D printing

services to individuals, businesses, and industries that need prototypes,
custom products, or small-batch manufacturing.

• Customized Products: Entrepreneurs can specialize in creating and selling

custom products, such as personalized accessories, medical implants, or
orthopedic devices.

• Print-on-Demand Platforms: Establishing an online platform where customers

can upload their designs and order 3D-printed products.

4. Research and Development:

• R&D Engineers: Professionals engaged in research and development to

advance the technology, improve printing processes, and develop new
materials.

• Innovation Consultants: Experts who guide businesses on integrating 3D

printing into their processes, identifying opportunities for innovation and
efficiency.

5. Quality Assurance and Certification:

• Quality Control Specialists: Professionals responsible for ensuring the quality

of 3D-printed products, including inspections, testing, and certification
processes.

6. Supply Chain and Logistics:

 • Supply Chain Managers: Experts who optimize the supply chain for additive
manufacturing, ensuring a smooth flow of materials and products.

7. Medical and Dental Applications:

• Bioprinting Specialists: Professionals involved in 3D printing biological tissues

and organs for medical applications.

• Dental Technicians: Specialists using 3D printing for the production of dental

implants, crowns, and other prosthetics.

8. Environmental Sustainability:

• Recycling and Sustainability Experts: Individuals working on developing and

implementing recycling solutions for 3D printing materials to reduce
environmental impact.

As the field of additive manufacturing continues to evolve, new opportunities are likely to
emerge, making it an exciting and dynamic space for employment and entrepreneurship.