Experimental investigation into the impact of acetone vapour jet drilling of 3D printed material

Purpose This study aims to investigate the effects of non-traditional processing techniques on the surface quality and thermal characteristics of parts manufactured from acrylonitrile butadiene styrene (ABS) using fused deposition modelling (FDM) additive manufacturing (AM). Acetone vapour treatment is applied to enhance surface polish and minimize material waste. Design/methodology/approach An experimental approach was adopted to investigate the impact of acetone vapour jet drilling on three-dimensional-printed materials. Specimens were fabricated using FDM with polylactic acid and ABS as the primary materials. A custom-built acetone vapour jet system was used to drill holes in the printed samples under controlled temperature, pressure and exposure time. The drilled holes were analysed for dimensional accuracy, surface roughness and material integrity using optical microscopy and scanning electron microscopy. A comparative assessment with conventional mechanical drilling was performed to evaluate the efficacy and limitations of the vapour jet method. The experimental results were statistically analysed to determine the influence of process parameters on hole quality and material deformation. Findings Removal of extra material substantially improves surface smoothness through extremely extended exposure times to acetone vapour. Increasing melting temperatures, enthalpies indicate superior heat resistance along with finer finishes achieved after treatment, according to a study. Originality/value This work advances the area of AM in showing how effectively acetone vapour treatment can enhance the surface quality and thermal characteristics of ABS parts made using FDM. Attention is drawn on how unusual processing techniques are used to solve common problems in traditional post-processing procedures, including material waste and uneven surface finish.