Enhancing Surface Finish in FDM 3D Printing: The Impact of a Spherical Ironing Tool

This study aims to evaluate the functionality and effectiveness of a new tool for ironing 3D printed components using FDM technology. The ironing process draws inspiration from the ball burnishing process, employing a spherical tool that, by exerting pressure, modifies the component's surface. The process involves heat transfer between the tool and the component to soften and deform the surface more easily. A theoretical analysis of the resulting surface roughness following this process was conducted to identify the parameters at play and their influence. It was found that the two main parameters are the fillet radius and the distance between passes. Additionally, practical tests were carried out to confirm the hypotheses, revealing the influence of three other parameters: tool Z-axis positioning, temperature, and movement speed. The surface after treatment exhibits an average roughness of Ra = 0.378 μm, significantly better than values obtained with ironing performed with the nozzle and with quality comparable to grinding. This lays the groundwork for possible future optimization of parameters based on the component's characteristics and the material used.