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<p>Additive manufacturing (AM) is a layer-by-layer fabrication process that enables complex rapid prototyping and offers flexibility for applications in aerospace, biomedical, and industrial product development. Fused deposition modeling (FDM) is a cost-effective and user-friendly additive manufacturing method. It is widely used to produce physical models for prototyping and low-volume production. However, FDM parts often exhibit anisotropic mechanical properties and weak interlayer adhesion. Poor surface quality and the need for post-processing also limit its use in engineering applications. This study proposes an integrated approach that combines FDM, silicone rubber molding, and vacuum casting. The goal is to improve surface finish and mechanical performance in prototype fabrication. The experimental results indicate that ethanol solution immersion provides better surface quality improvement for 3D-printed parts than ethanol vapor treatment. Immersing the printed parts in a 60&#xa0;°C ethanol solution for 3&#xa0;min is identified as the optimal processing condition. To accommodate the dimensional changes caused by immersion, it is recommended to apply size compensation of approximately 2% in the X and Y directions and 10% in the Z direction during the design stage. In addition, polyurethane (PU) infiltration significantly enhances the compressive strength of printed parts. The most notable improvement was observed in samples with 20% infill density. This is attributed to the high toughness and effective pore-filling ability of PU. Based on the results of three validation samples, the proposed method in this study can fabricate prototypes with both high surface quality and excellent mechanical performance. These findings demonstrate the practical value and potential of this technique in additive manufacturing applications. The proposed process enhances product quality while reducing waste from trial-and-error prototyping and excessive machining, supporting sustainable production practices. These contributions align with the United Nations Sustainable Development Goals (SDGs), particularly SDG 9 and SDG 12.</p>

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An innovative technology for manufacturing prototypes with excellent surface quality and mechanical properties

  • 期刊论文

  • 发表日期：

    2025年11月12日

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  • Chil-Chyuan Kuo,
  • Zhe-Zhi Lin,
  • Armaan Farooqui,
  • Shu-Yu Hsieh,
  • Chia-Hsun Yu,
  • Song-Hua Huang,
  • Shih-Feng Tseng

摘要

Additive manufacturing (AM) is a layer-by-layer fabrication process that enables complex rapid prototyping and offers flexibility for applications in aerospace, biomedical, and industrial product development. Fused deposition modeling (FDM) is a cost-effective and user-friendly additive manufacturing method. It is widely used to produce physical models for prototyping and low-volume production. However, FDM parts often exhibit anisotropic mechanical properties and weak interlayer adhesion. Poor surface quality and the need for post-processing also limit its use in engineering applications. This study proposes an integrated approach that combines FDM, silicone rubber molding, and vacuum casting. The goal is to improve surface finish and mechanical performance in prototype fabrication. The experimental results indicate that ethanol solution immersion provides better surface quality improvement for 3D-printed parts than ethanol vapor treatment. Immersing the printed parts in a 60 °C ethanol solution for 3 min is identified as the optimal processing condition. To accommodate the dimensional changes caused by immersion, it is recommended to apply size compensation of approximately 2% in the X and Y directions and 10% in the Z direction during the design stage. In addition, polyurethane (PU) infiltration significantly enhances the compressive strength of printed parts. The most notable improvement was observed in samples with 20% infill density. This is attributed to the high toughness and effective pore-filling ability of PU. Based on the results of three validation samples, the proposed method in this study can fabricate prototypes with both high surface quality and excellent mechanical performance. These findings demonstrate the practical value and potential of this technique in additive manufacturing applications. The proposed process enhances product quality while reducing waste from trial-and-error prototyping and excessive machining, supporting sustainable production practices. These contributions align with the United Nations Sustainable Development Goals (SDGs), particularly SDG 9 and SDG 12.