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Laser polishing of thermoplastics fabricated using fused deposition modelling

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Abstract

Fused deposition modelling (FDM) is a technique of additive manufacturing (AM) which is capable of fast construction of plastic prototypes. AM technology has been utilised in orthopaedics and traumatology to fabricate patient-specific models, surgical guides, and implants. However, the layering build-up by FDM usually generates a deleterious rough surface that limits its application to items such as surgical guide and surgical operating guide, because these items require a highly resolved surface quality. The advancement of laser polishing has been offering a cost-effective and fast manufacturing solution for FDM-constructed patient-specific guides and implants. This investigation explores application potential using a contactless laser scanning to improve the surface quality of FDM-fabricated thermoplastics. The results show that a maximum [68%] reduction in surface roughness was achieved at 3 W CO2 laser power, 150 mm/s scan speed, 30 ms scan delay and 0.025 mm line gap. Laser polishing is suitable to treat the surface of polylactic acid (PLA). This study provides data which supports a new approach to the manufacture of AM-fabricated thermoplastics utilising a laser scanning technique to improve the surface quality.

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Acknowledgements

The authors are thankful to Mr. Khu Vu in the Research School Physics, Dr. Hua Chen in the Centre of Advanced Microscope, and Chao Hu in the Research School of Engineering at the Australian National University for the technical assistance.

Funding

This work has been financially supported by the Australian Research Council PhD Scholarship (LP150100343).

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Authors and Affiliations

  1. Trauma and Orthopaedic Research Laboratory, Department of Surgery, The Medical School, The Australian National University, Building 131, Garran Road, Canberra, ACT, 2601, Australia

    Yuan Chai & Rachel W. Li

  2. Department of Immunology and Infectious Disease, John Curtin School of Medical Research, The Australian National University, Acton, ACT, 0200, Australia

    Rachel W. Li

  3. Trauma and Orthopaedic Research Unit, The Canberra Hospital, Yamba Drive, Garran, ACT, 2605, Australia

    Diana M. Perriman & Paul N. Smith

  4. Research School of Engineering, College of Engineering and Computer Science, Australian National University, Acton, ACT, 2601, Australia

    Song Chen & Qing-Hua Qin

Authors
  1. Yuan Chai
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  2. Rachel W. Li
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  3. Diana M. Perriman
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  4. Song Chen
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  5. Qing-Hua Qin
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Correspondence to Rachel W. Li.

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Chai, Y., Li, R.W., Perriman, D.M. et al. Laser polishing of thermoplastics fabricated using fused deposition modelling. Int J Adv Manuf Technol 96, 4295–4302 (2018). https://doi.org/10.1007/s00170-018-1901-5

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  • DOI: https://doi.org/10.1007/s00170-018-1901-5

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