In-process laser heating for surface finishing of carbon fiber reinforced nylon in fused filament fabrication

Parts fabricated using Fused Filament Fabrication (FFF), the most widely utilized polymer additive manufacturing process, typically exhibit a rough side surface finish due to the extrusion process’s inherent physics. While carbon fiber-reinforced materials enhance mechanical strength and expand the applications of FFF, they tend to worsen the surface finish due to reduced filament viscosity. This work presents a laser-assisted, in-process surface smoothing technology that reduces surface roughness from 28 microns to 11 microns. This technology is compatible with both flat and curved surfaces. The comparison between carbon fiber-reinforced nylon and homogeneous materials, as well as the process’s effect on mechanical behavior, are also explored. The proposed technology improves dimensional accuracy and ensures uniform stress distribution in materials, making it suitable for batch production applications requiring high tolerance and strength, such as high-end furniture, vehicles, medical devices, and aerospace components.