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Surface finish enhancement in fused deposition modeling of PLA using chloroform: a comprehensive characterization study

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Abstract

Fused Deposition Modelling is an additive manufacturing method that is gaining popularity to create complex parts. However, the printed product often suffers from poor surface finish. Although various chemical treatment methods have been proposed to enhance the surface finish quality of printed parts, the treatment mechanism and its effect on the mechanical properties of the parts have not been well identified and characterized. The focus of this study is to investigate the impact of chloroform solution concentrations and immersion times on the surface roughness, tensile strength, and impact strength of polylactic acid-printed parts after chemical dipping treatment. Additionally, it seeks to understand and characterise the mechanism through which chloroform affects surface properties and alters mechanical characteristics. For this purpose, a central composite design was used to design a set of 13 experiments with varying levels of concentration and immersion time. The mechanisms underlying the changes in surface roughness, tensile strength, and impact strength were evaluated using scanning electron microscopy and energy dispersive X-ray analyses to evaluate the topography and elemental composition of the treated surface. Thermogravimetric analysis and differential scanning calorimetry were employed to investigate the change in thermal properties and crystallinity. The results reveal a significant reduction in surface roughness on sloped and flat surfaces. Additionally, the treated specimen demonstrated higher impact strength, while a decrease in tensile strength was observed. In addition, structural and elemental compositional changes were noted to the outer surface layer of the specimens.

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Data availability

The data that support the findings of this study are available from the corresponding author, AAF, upon reasonable request.

Abbreviations

FDM:

Fused deposition modelling

PLA:

Polylactic acid

CVS:

Cold vapor smoothing

ABS:

Acrylonitrile butadiene styrene

HVS:

Hot vapor smoothing

ANOVA:

Analysis of variance

SRI:

Surface roughness improvement (SRI)

DCM:

Dichloromethane

TGA:

Thermogravimetric analysis

DSC:

Differential scanning calorimetry

CCD:

Central composite deposit

EDX:

Energy dispersive X-ray (EDX)

FESEM:

Field emission scanning electron microscope

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Acknowledgements

This work was supported in part by the Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia, and Ministry of Higher Education (MOHE) Malaysia under the Fundamental Research Grant Scheme (FRGS) FRGS/1/2020/TK0/UNIM/02/16.

Funding

This study was funded by the Ministry of Higher Education (MOHE) Malaysia under the Fundamental Research Grant Scheme (FRGS) FRGS/1/2020/TK0/UNIM/02/16.

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Authors and Affiliations

  1. Department of Mechanical, Materials and Manufacturing Engineering, University of Nottingham Malaysia, Semenyih, Malaysia

    Ali Akhavan Farid, Tshai Kim Yeow, Zachary Kavan Jim, Choo Zhek Sheng & Kamesh Krishnamurariu

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  1. Ali Akhavan Farid
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  2. Tshai Kim Yeow
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  3. Zachary Kavan Jim
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Correspondence to Ali Akhavan Farid.

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Akhavan Farid, A., Tshai, K., Jim, Z. et al. Surface finish enhancement in fused deposition modeling of PLA using chloroform: a comprehensive characterization study. Prog Addit Manuf (2024). https://doi.org/10.1007/s40964-024-00649-2

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