Investigating the Effects of Acetone Vapor Treatment Conditions and Post Drying Methods on Surface Roughness and Tensile Strength of 3D Printed ABS Components
Authors: Bae Heechang Alex , Kinney Mickenzie , Scheff Tyler , Michaelis Matthew , Hossain Awlad 
Published: February 2024

Additive manufacturing (AM) or 3D printing is a fabrication process, usually layer upon layer, of joining materials to make the desired objects directly from a 3D model. 3D printing allows for complex geometries that would be difficult, if not impossible to create using traditional subtractive methods such as milling, grinding, casting, etc. The nature of the additive process also allows the user to avoid or minimize costs that would be incurred if setting up with a traditional subtractive process. With AM there is no need for fixtures, tooling, or multiple processes to complete the part, which allows AM processes to operate with greater flexibility and lower costs. This flexibility allows 3D printing to produce end-use products for many different applications with lower initial investment, maintenance, labor costs and operating costs.

Our research specifically focuses on the Fused Deposition Modeling (FDM) process. Fused Deposition Modeling is a process in which the chosen filament is melted, extruded through a nozzle, and then deposited layer by layer as described above. This FDM process is used not only in rapid prototyping as it was initially intended, but also in mass production of finished products as it holds many advantages over the traditional methods. In 3D printing, parts are usually built in discrete layers, and this often results in a certain amount of structural uncertainty in the form of discontinuities, voids, and poor inter-layer bonding. The 3D printed parts are increasingly being used for end-use products that are subject to higher tolerance, quality, uniformity, and surface finish requirements. Hence, to see greater market penetration, the amount of structural uncertainty must be reduced.

In our previous research, we successfully investigated the differences in the ultimate strength and fatigue life for 3D printed Acrylonitrile Butadiene Styrene (ABS) components built by various build/layer orientations. Our previous research also successfully highlighted the ultimate strengths and fatigue life, including SN Curves. However, there is a need for further research to improve the surface finish and the tensile strength of the 3D printed ABS components. This research explores the effects of the surface treatment on the tensile strength of the 3D printed ABS components with various layup-orientation. In this study, Acetone Vaper Smoothing (AVS) was used as the surface treatment of the 3D printed ABS components. Our research found that the AVS method reduces stress concentration and structural uncertainty of the 3D printed ABS components to improve the tensile strength. However, these results only occurred after optimizing the acetone vapor exposure and improving the drying methods since acetone can weaken the layer bonding of the ABS and reduced the tensile strength of the 3D printed ABS components in certain situations. This research also provides the optimal conditions of the acetone vapor exposure time and the drying method.