Thermal simulation for enhanced control in innovative ironing processes on 3D-printed components

This study investigates an innovative surface finishing process for 3D-printed components using Material Extrusion (MEX). By applying controlled heating to the outer layer with a heated, semi-spherical tip, surface quality can be enhanced without adding material, effectively reducing imperfections caused by nozzle deposition. Using a prototype tool with distinct thermal properties, simulations were conducted to assess the optimal process parameters, including tool temperature, movement speed, and depth of influence within the material. Thermal simulations of the tool were performed to analyse temperature distribution and efficiency, identifying potential heat losses. Additionally, interactions between the tool tip and the material were simulated, highlighting temperature distribution at various depths. The simulations reliably model the tool's performance, providing a solid foundation for precise process parameter calibration while minimising reliance on experimental testing. Analyses conducted on PLA, PETG, ABS, PEEK, and PEKK demonstrated a clear correlation between speed and temperature in achieving optimal results. For materials with a high glass transition temperature, either a lower speed or a higher tool temperature is required, depending on the material's thermal properties.