The influence of vapour post-processing of ABS 3D printed parts on impact strength

Purpose Additive manufacturing, commonly referred to as 3D printing, has revolutionised the manufacturing of polymer components by providing additional design flexibility, reducing prototyping timelines and unit costs for low to medium production volumes. Despite the advantages of widespread adoption, 3D printing still faces challenges due to the inherent variability in mechanical strength and the resultant surface quality. The post processing of acrylonitrile butadiene styrene (ABS) 3D printed components via vapour smoothing (VS) provides the novel opportunity to enhance component optical and aesthetic functionality whereby a glossy surface finish can be produced. Design/methodology/approach Within this study, a design of experiment approach is applied to quantify the effect that 3D printing parameters and VS have on the resulting impact strength. In particular, whether print direction and layer height parameters influence the amount of gloss of the surface. Findings The purpose of this study/paper was to show that 3D printed components post-processed with VS can improve gloss, this was achieved with a mean gloss unit range of 29.9–51.1. This is a 556% increase when compared to parts that have not been post processed. In addition, the research also found that when the applying a glossy surface the impact strength can be reduced by up to 41.8%. Research limitations/implications The main implication is that VS can be detrimental to some products. Practical implications The main practical implication is that VS is cost-effective when considering other surface treatments. However, for designers and manufacturers there is a compromise to consider if the product requires resistance to sudden forces for improved durability and reliability. Social implications The social implication is that parts can fail after VS more readily than non-VS parts. This can affect people’s lives directly and can influence material sustainability. Originality/value This paper aims to contribute to the understanding of 3D printed materials resulting in impact strength following post-processing via VS. The methodology proposed could be effectively used to enhance the surface finish of components produced through 3D printing and expand the functionality beyond current applications. In addition, the outputs of the research further expand the application of 3D printed components for optical, aesthetic enhancement and Class A surface generation for automotive body parts.