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Post-processing brings 3D printed concepts to life
Articles- Aug 24,24
Post-processing techniques are essential to make most 3D printed prototypes function as intended. However, it is important to select the most appropriate post-processing steps without adding extra time and unnecessary costs, says Emily Newton.
Ongoing 3D-printing advancements have encouraged more people to explore how to apply the improvements for prototyping. Post-processing in 3D printing allows adding strategic features to meet clients’ demands or develop innovative products. Additionally, well-chosen post-processing techniques support customisation that helps users determine the most feasible characteristics for new or updated items.
What is post-processing in 3D printing?
People apply post-processing techniques in 3D printing to change specific characteristics. The options comprise three categories:
- Subtractive
- Additive
- Property-changing
Most individuals cannot expect to use their creations without going through some of these steps. The parts do not have the necessary visual and performance-related attributes until processing occurs. For example, unprocessed parts often have a ridged or lined appearance or lack the dimensional accuracy needed for precise applications. Many are also not sufficiently durable for their intended uses until creators apply post-processing methods.
However, designers, engineers and others can determine the most appropriate post-processing steps as they examine their printed prototypes. The goal is to find truly beneficial options without choosing things that will merely add extra time and unnecessary costs.
Subtractive methods involve removing something from a 3D-printed item. They are among the most widely used options since one example consists of taking off support structures. Some 3D-printed creations include overhangs or sharp angles. However, some people design items to feature built-in supports rather than removable ones. The most common practice is throwing those parts away after use, which creates waste, leaving some parties eager to look for alternatives.
Additive options put things onto printed parts, sometimes to increase strength or give the item desired mechanical properties. Property-changing techniques involve chemical or thermal treatments to make components more durable, smoother or feature other beneficial attributes.
How can people apply post-processing in 3D printing?
Since one of the most common post-processing steps concerns removing a printed item’s supports, people find that many proposed prototypes need them. They prevent areas with bridges, sharp angles and overhanging sections from collapsing as the printed part cures.
However, there are also numerous lesser-considered post-processing options. They include wrapping parts in foil or choosing localised melting to reduce surface-level scratches and other damage.
Additionally, some companies have branded processes and products to support customers’ needs. One example is an automated cabinet that cleans and polishes 3D-printed parts. It works up to 80% faster than conventional methods, finishing components in as few as 15 minutes. That highlights how many clients and companies prioritise automation to meet existing or emerging needs.
Those interested in post-processing techniques should always take individualised approaches by considering particular project needs and which options will most likely get the desired results. For example, someone with solely aesthetic goals may apply paint to their prototype. Tumbling is better than vibrating if the part needs polishing but has delicate areas.
Several heat treatments improve the strength of prototype components through reduced tensile pressure. These options can also increase density or facilitate forming a part into its intended shape. Hot isostatic pressing is frequently chosen for industries such as aerospace or medicine, where failures could be catastrophic. It brings a part to 100% theoretical density, eliminating porosity and defects.
How are post-processing techniques changing 3D printing?
People have attempted numerous creative ways to apply post-processing in 3D printing. Their work will undoubtedly improve prototyping and increase functionality.
Using shot blasting to make orthopedic braces more comfortable
3D printing has become a popular way to make customised medical products more efficiently. They may require less specialised training to fabricate compared to conventionally created items.
In one example, a company used an automated shot-blasting machine to improve the surface texture of custom-made arm braces. Making the devices as smooth against the skin as possible increases patient comfort, which could make people more likely to comply with their providers’ orders. This approach caused a 70% reduction in post-processing time and freed workers to do other tasks.
Applying a patented process to improve mechanical performance
A company explored new possibilities by patenting a new Continuous Fibre Injection Process (CFIP). It involves inserting short, continuous fibers — such as those made from carbon or glass — into dedicated tubular cavities that people include as part of their parts’ designs. The fibers travel via a resin that significantly strengthens a component’s structure once it cures.
Those familiar with CFIP say it broadens 3D printing options by allowing users to change an item’s properties through post-production rather than design decisions. Additionally, the fiber injection process enables integral bonding throughout the part, offering more robust results than traditional options, such as applying adhesives.
Accelerating part-finishing time with a new technique
Researchers have achieved a breakthrough for post-processing in 3D printing by developing a technique that shortens the time required to finish metal parts made for critical machines. The process typically requires people to print components and then remove them from printers to ensure they meet strict specifications and tolerances. The creators can then perform the necessary post-processing steps.
This group combined 3D printing, automated machining, touch-sensitive measurement technologies and laser scanning. It sought to significantly reduce the time required to get a recently made part ready for use in applications that require exact precision. Tests showed the new technique finished parts 67 minutes faster than conventional options. That result could make a significant difference, especially when employees must prototype multiple options in limited time windows.
Post-processing in 3D printing creates new opportunities
The best ways to use post-processing in 3D printing depend on a project’s specific needs, a client’s requests, whether the component must withstand harsh conditions and more. However, post-processing techniques are essential to make most printed prototypes function as intended. Therefore, designers, engineers and other involved parties should consider the must-have characteristics and evaluate options according to those necessities.
About the author:
Emily Newton is a tech and industrial journalist and the Editor-in-Chief of Revolutionized magazine. Subscribe to the Revolutionized newsletter for more content from Emily.
Post-processing in 3D Printing
3D printed prototypes
3D Printing
Emily Newton
Continuous Fibre Injection Process
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