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]]>How to Electroplate SLS Nylon 3D Prints: A Guide to Metallic Finishes
Electroplating has become a popular method for enhancing the aesthetics and functionality of 3D-printed parts. While it’s commonly applied to SLA or FDM prints, SLS (Selective Laser Sintering) nylon prints present a unique opportunity for electroplating due to their excellent mechanical properties and versatility. If you’ve ever wondered how to transform your SLS nylon 3D prints into durable, metallic-finished components, this guide will walk you through the process step by step.
Why Electroplate SLS Nylon 3D Prints?
Electroplating on SLS nylon offers several advantages:
Durability: The metallic layer protects the print from wear and tear.
Aesthetics: A shiny, metallic finish transforms a functional part into an eye-catching masterpiece.
Functionality: The metal coating adds electrical conductivity and increased heat resistance.
Customization: Use different metals like copper, nickel, or gold for specific applications.
SLS nylon is an ideal substrate for electroplating due to its porous surface, which allows for strong adhesion of conductive coatings and metal layers.
Materials and Tools You’ll Need
SLS 3D Print: Except for TPU and PP materials, all other SLS-printed materials can be electroplated.
Sanding Tools: Sandpaper (various grits), or using professional tumbling machine with ceramic media.
Conductive Coating: Conductive paint or spray (e.g., silver, graphite, or copper-based)
At IN3DTEC Factory, we can electroplate the parts as large as 1 meter.
Contact us through [email protected], or upload your files to our online quoting system to get an instant quote
SLS Nylon 3D Prints Electroplating Setup
- Electroplating solution (specific to the metal you plan to use)
- Power supply (DC source)
- Electrodes (anode metal corresponding to the plating solution)
- Cleaning Supplies: Isopropyl alcohol or other cleaning agents
- Protective Gear: Gloves, goggles, and a well-ventilated workspace
Step-by-Step Guide to Electroplating SLS Nylon
Step 1: Prepare the Surface
SLS prints often have a powdery or rough texture that must be smoothed for optimal electroplating results.
- Clean the Print: Remove excess powder from the surface using compressed air or brushing.
- Sanding: Use progressively finer sandpaper (follow 400-600-800-1200-2000) to smooth the surface. For a polished finish, apply a polishing compound after sanding.
- Wash and Dry: Use isopropyl alcohol to remove dust and oils, then let the print dry completely.
Step 2: Apply a Conductive Coating
Since nylon is non-conductive, applying a conductive coating is crucial for the electroplating process.
- Choose the Right Coating: Graphite-based or silver conductive paints work well for nylon.
- Apply Evenly: Spray or brush on the coating, ensuring full coverage, especially in intricate areas.
- Dry Thoroughly: Allow the conductive layer to cure as per the manufacturer’s instructions.
Step 3: Set Up the Electroplating System
Prepare your electroplating bath according to the chosen metal.
- Electroplating Solution: Mix the solution as directed, ensuring the concentration matches the metal you’re using (e.g., nickel, copper, or gold).
- Attach Electrodes:
- Anode: Use a metal electrode of the same type as your plating solution (e.g., copper for copper plating).
- Cathode: Connect your prepared SLS print to the negative terminal of the power supply.
- Immerse the Print: Submerge the part in the electroplating bath, ensuring all conductive areas are covered.
Step 4: Electroplate the Part
- Adjust the Current: Set the power supply to the appropriate voltage and current for your plating process. A lower current ensures a smoother, more uniform coating.
- Plating Time: Monitor the process, as plating time varies depending on the desired thickness.
- Rotate if Needed: For complex shapes, rotate the part periodically to ensure even coverage.
Step 5: Post-Plating Finishing
Once the desired metal layer thickness is achieved, carefully remove the print from the bath.
- Rinse Thoroughly: Use clean water to rinse away residual solution.
- Polish the Surface: Use a polishing compound to enhance the metallic shine.
- Optional Sealant: Apply a clear protective coat to prevent tarnishing or corrosion.
Tips for Success
- Start Small: Practice on test pieces before plating a critical part.
- Monitor Closely: Overplating can lead to uneven surfaces or cracks.
- Experiment with Metals: Copper is a great base layer; additional layers of nickel or gold can enhance the finish.
Applications for Electroplated SLS Nylon Parts
Electroplating expands the range of applications for SLS nylon prints:
- Functional Prototypes: Stronger and more durable parts for testing.
- Decorative Items: High-quality metallic finishes for display models and ornaments.
- Conductive Components: Electroplated parts for electronics or RF shielding.
Challenges and Considerations
- Porosity of Nylon: While helpful for adhesion, excess porosity can result in uneven plating. Proper sealing with conductive paint helps address this.
- Cost: Electroplating involves additional materials and equipment, so factor this into your project budget.
- Safety: Work in a well-ventilated area and follow safety guidelines for chemicals and electricity.
Conclusion
Electroplating SLS nylon 3D prints is a powerful technique that combines the flexibility of additive manufacturing with the durability and beauty of metal finishes. With the right preparation and tools, you can create parts that are not only functional but also visually striking.
By following this guide, you’re well on your way to transforming your SLS nylon prints into metallic masterpieces, opening the door to countless creative and industrial applications.
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]]>Electroplating Metal 3D Prints: A Guide to Enhancing Surface Finishes
When it comes to 3D printing, metal prints already offer exceptional strength, durability, and a professional appearance. However, even metal prints can benefit from a touch of refinement. Electroplating, the process of adding a metallic layer through an electrochemical process, can enhance the surface quality, durability, and functionality of metal 3D prints. But is it possible to electroplate metal prints, and how does it work? Let’s explore this exciting technique.
Why Electroplate Metal 3D Prints?
Even though metal 3D prints are inherently robust, electroplating can further enhance their properties:
- Improved Aesthetics: Achieve a polished, uniform finish or even a different metallic appearance, such as gold or chrome.
- Corrosion Resistance: Add a protective coating that prevents oxidation or environmental damage.
- Increased Durability: Enhance wear resistance for functional parts.
- Electrical Conductivity: Optimize the surface for electronics or conductive applications.
Electroplating is particularly beneficial for industries like aerospace, automotive, and jewelry, where aesthetics and performance go hand in hand.
Understand more about the electroplating process.
Can You Electroplate Metal 3D Prints?
Yes, metal 3D prints can be electroplated, and the process is often more straightforward than plating plastic prints. The primary reason is that metal substrates are typically conductive, eliminating the need for a conductive coating step. However, the success of the electroplating process depends on factors such as the type of metal used in the 3D print and the plating metal.
Commonly used metals in 3D printing, like stainless steel, titanium, and aluminum, are excellent candidates for electroplating.
Electroplating Metal 3D Prints: Step-by-Step Guide
Step 1: Surface Preparation
- Clean the Print: Remove oils, dust, or residue from the surface using isopropyl alcohol or an ultrasonic cleaner.Dry the print 4-5 hours in the oven.
- Smooth the Surface: Sand or polish the part to remove imperfections. A smooth surface ensures a uniform electroplated finish.Try to use tumbling if the parts are more difficult to be manually polished.
Step 2: Apply a Base Layer (If Necessary)
Some metals, like aluminum, require a base layer (e.g., zincate or copper) before electroplating because they don’t adhere well to certain plating solutions.
Step 3: Prepare the Electroplating Setup
- Electroplating Bath: Choose a solution compatible with your desired plating metal (e.g., nickel, copper, or gold).
- Power Supply: Use a DC power supply for controlling the current during the plating process.
- Anode and Cathode Setup: Attach your metal 3D print to the cathode (negative terminal) and use the plating metal as the anode (positive terminal).
Step 4: Electroplate the Metal Print
- Immerse the Print: Submerge the print into the electroplating bath.
- Set the Current: Adjust the current to match the plating solution specifications.
- Monitor the Process: The plating process can take minutes to hours depending on the desired thickness.
Step 5: Post-Plating Finishing
- Rinse: Wash the part in distilled water to remove plating solution residue.
- Polish: Buff the plated surface to achieve the desired shine or texture.
- Seal the Surface: For some metals, apply a protective coating to prevent tarnishing or oxidation.
Tips for Electroplating Success
- Choose Compatible Metals: Not all combinations of substrate and plating metals adhere well. Research compatibility beforehand.
- Avoid Overplating: Excess plating thickness can lead to uneven surfaces or peeling.
- Test Small Parts First: Before electroplating a critical piece, practice on smaller or less important parts.
- Use Proper Safety Measures: Work in a ventilated area and use gloves to handle chemicals safely.
Applications of Electroplated Metal 3D Prints
- Jewelry: Enhance the appearance of 3D-printed gold, silver, or platinum pieces.
- Functional Components: Add wear-resistant coatings to industrial parts.
- Decorative Items: Improve the polish and aesthetic appeal of sculptures or consumer products.
Challenges to Consider
- Surface Porosity: Some metal 3D printing techniques (e.g., binder jetting) result in porous surfaces that may require sealing before plating.
- Cost: Electroplating setups and solutions can add to project costs.
- Skill Requirement: Proper preparation and technique are critical for high-quality results.
Need the electroplating finish on your metal 3d prints? Submit your project details, and we will offer you a cheapest and affordable cost for your parts.
Conclusion
Electroplating metal 3D prints is not only possible but also a powerful way to enhance their appearance and functionality. By following the right steps and understanding the compatibility between your print material and plating metal, you can create durable, eye-catching, and professional-quality parts.
Whether you’re producing jewelry, functional prototypes, or decorative items, electroplating is a versatile technique that can elevate your 3D printing projects to the next level.
More article:
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]]>Electroplating vs. Physical Vapor Deposition (PVD) Coating: A Comparative Analysis
In the realm of surface finishing and coating technologies, Electroplating and Physical Vapor Deposition (PVD) stand out as two widely adopted methods. Both techniques are essential in enhancing the appearance, durability, and functionality of metal surfaces across various industries. However, they differ significantly in their processes, applications, and benefits. Let’s delve into a comparative analysis of Electroplating and PVD coating.
Electroplating: An Overview
Electroplating is a process that uses an electric current to deposit a thin layer of metal onto a substrate. This method involves immersing the substrate and a metal anode in an electrolyte solution. When an electric current is applied, metal ions from the anode dissolve and are deposited onto the substrate, forming a coherent metal coating.
Applications of Electroplating:
– Corrosion Resistance:For metals, Electroplating is extensively used to protect metals from corrosion. Commonly plated metals include zinc, nickel, and chromium. For plastics, it can give them a metallic appearance and a mirror-like finish.
– Aesthetic Enhancement: It is often employed to enhance the appearance of items like jewelry, automotive parts, and household fixtures.
– Electrical Conductivity: Electroplating with metals like gold and silver is used in electronics to improve electrical conductivity and solderability.
Several of Projects of electroplating parts by IN3DTEC
Advantages of Electroplating:
– Cost-Effective: Generally, electroplating is less expensive compared to other coating methods.
– Versatility: It can coat a wide range of metals and alloys.
– Smooth Finishes:The process can produce very smooth and uniform coatings.
Limitations of Electroplating:
– Environmental Impact: The use of toxic chemicals and heavy metals poses significant environmental and health hazards.
– Thickness Limitation: The coating thickness is relatively limited, which might not be sufficient for some applications.
– Adhesion Issues:The bond between the coating and the substrate can be weaker compared to other methods.
Physical Vapor Deposition (PVD) Coating: An Overview
Physical Vapor Deposition (PVD) is a vacuum-based process where materials are vaporized and then deposited onto a substrate to form a thin film. PVD encompasses various techniques, such as sputtering and evaporation, to achieve the desired coating.
Applications of PVD Coating:
– Tooling and Cutting Instruments: PVD coatings are widely used to enhance the hardness and wear resistance of cutting tools and dies.
– Decorative Finishes: PVD is utilized for providing durable and aesthetically pleasing finishes on consumer goods like watches and electronic devices.
– Protective Coatings: It offers excellent resistance to corrosion and wear, making it suitable for aerospace and automotive components.
Advantages of PVD Coating:
– High Durability:PVD coatings are known for their exceptional hardness and wear resistance.
– Environmental Friendliness:The process is cleaner and more environmentally friendly compared to electroplating.
– Superior Adhesion: PVD provides excellent adhesion to the substrate, resulting in a long-lasting coating.
Limitations of PVD Coating:
– Higher Costs: PVD coating is generally more expensive due to the complexity of the process and equipment required.
– Process Complexity:The vacuum environment and high temperatures involved can limit the size and shape of the components that can be coated.
– Preparation Requirements: Substrates often require extensive preparation to ensure successful coating adhesion.
Comparative Analysis
- Process and Application:
– Electroplating is a simpler, more cost-effective process suitable for mass production and a variety of metals & plastics. It is ideal for applications where a moderate level of corrosion resistance and aesthetic enhancement are required.
– PVD coating, while more complex and costly, offers superior durability, environmental benefits, and exceptional performance in high-stress applications.
- Environmental and Health Impact:
– Electroplating poses significant environmental and health risks due to the use of hazardous chemicals.
– PVD is a more environmentally friendly option, producing fewer hazardous byproducts.
- Coating Properties:
– Electroplated coatings are generally softer and less durable than PVD coatings.
– PVD coatings provide enhanced hardness, wear resistance, and superior adhesion, making them suitable for high-performance applications.
If your component requires this kind of follow-up treatment, feel free to contact our team for an instant quote, [email protected]
Or find this selection under SLA-Standard ABS-Electroplating from our online store
Conclusion
Choosing between electroplating and PVD coating depends on the specific requirements of the application, including cost, environmental considerations, and the desired properties of the final product. While electroplating offers a cost-effective solution for a wide range of applications, PVD coating provides superior durability and environmental benefits, making it the preferred choice for high-performance and environmentally conscious applications.
Understanding the strengths and limitations of each method allows for informed decision-making, ensuring the optimal surface finishing solution for various industrial needs.
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]]>8 Things You Need to Know About Anodizing Aluminum
Introduction:
Aluminum is a versatile metal that is widely used in various industries for its lightweight, durable, and corrosion-resistant properties. One of the most popular surface treatment methods for aluminum is anodizing. Anodizing aluminum not only enhances its appearance but also improves its resistance to wear and corrosion. In this blog post, we will explore eight important things you need to know about anodizing aluminum.
1. What is Anodizing?
Anodizing is an electrochemical process that forms a protective oxide layer on the surface of aluminum. It involves immersing the aluminum in an electrolyte bath and passing an electric current through it. This causes oxygen ions to combine with the aluminum atoms, creating a thick and durable oxide layer.
2. Benefits of Anodizing Aluminum:
Anodizing offers several advantages for aluminum products. Firstly, it significantly improves the metal’s corrosion resistance, making it suitable for outdoor applications. Secondly, anodized aluminum has enhanced wear resistance, making it more durable and long-lasting. Additionally, anodized aluminum provides an excellent base for coloring and dyeing, allowing for a wide range of aesthetic options.
3. Different Types of Anodizing:
There are three main types of anodizing processes for aluminum: Type I, Type II, and Type III. Type I anodizing, also known as chromic acid anodizing, produces a thin and porous oxide layer, primarily used for cosmetic purposes. Type II anodizing, or sulfuric acid anodizing, creates a thicker and more durable oxide layer, suitable for both decorative and functional applications. Type III anodizing, also called hardcoat anodizing, produces an even thicker oxide layer, resulting in superior wear and corrosion resistance.
4. Surface Preparation:
Before the anodizing process, proper surface preparation is crucial. The aluminum surface needs to be thoroughly cleaned to remove any dirt, grease, or oxide layers. This can be done through mechanical methods such as sanding or chemical cleaning. Surface preparation ensures that the anodized layer adheres well to the aluminum surface, resulting in a high-quality finish.
5. The Anodizing Process:
During anodizing, the aluminum part acts as the anode and is submerged in an electrolyte solution. A direct current is passed through the electrolyte, causing oxygen ions to react with the aluminum surface, forming the oxide layer. The thickness of the oxide layer can be controlled by adjusting the duration of the process. Once the desired thickness is achieved, the aluminum is rinsed and sealed to preserve the anodized layer.
6. Coloring and Dyeing:
Anodized aluminum can be further enhanced with color. The porous nature of the anodized layer allows dyes to penetrate and become trapped within the oxide structure. This results in a wide range of color options for anodized aluminum products. The colorants used are typically organic dyes or inorganic pigments, offering excellent fade resistance and durability.
7. Sealing the Anodized Layer:
After anodizing, the aluminum part undergoes a sealing process to close the pores of the oxide layer. Sealing improves the corrosion resistance and enhances the durability of the anodized finish. Common sealing methods include hot water sealing, steam sealing, and chemical sealing. The choice of sealing method depends on the specific application requirements.
8. Applications of Anodized Aluminum:
Anodized aluminum finds widespread use in various industries. It is commonly employed in architectural applications for its aesthetic appeal, weather resistance, and low maintenance requirements. Anodized aluminum is also utilized in the aerospace industry, automotive components, consumer electronics, and sporting goods. Its ability to combine functionality with visual appeal makes it a popular choice across diverse sectors.
Conclusion:
Anodizing aluminum is a highly effective surface treatment that enhances the properties and appearance of the metal. Understanding the anodizing process, its types, and the benefits it offers can help you make informed decisions when it comes to utilizing anodized aluminum in your projects. Whether you are looking to improve corrosion resistance, add color, or increase the durability of your aluminum products, anodizing provides an excellent solutio
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]]>Painting vs Powder Coating
When it comes to adding protective and decorative finishes to various surfaces, two popular methods have emerged: painting and powder coating. How to select the right one for your application?
In this article, we will explore the differences between painting and powder coatings, examining their processes, advantages & disadvantages, and environmental impacts. By understanding the unique characteristics of each method, you can knowingly decide which method is most suitable for your specific needs.
What is painting?
Painting involves the application of liquid paint using brushes, rollers, or spray guns. Paint consists of pigments, binders, solvents, and additives. Painting can be done manually or through automated systems. It requires skilled labor and can be time-consuming.
Adhesion: Paint adheres to the surface through mechanical bonding and chemical reactions.
Finish: Painting offers a wide range of finishes, including matte, satin, and glossy. It allows for customization with various colors, textures, and effects.
Thickness: The thickness of paint can vary depending on the desired coverage, typically ranging from a few micrometers to several tens of micrometers.
Curing: Paint requires a drying and curing process to achieve full hardness and durability.
Environmental Impact: Most paints may contain volatile organic compounds (VOCs), which contribute to air pollution. Water-based paints are a more environmentally friendly option.
Advantages：
- Multiple colors & surface finishes options
- Cost-effective
- Easy to use
- Repairability
Disadvantages：
- Painted surfaces may not be as durable or resistant to scratches, chips, or corrosion compared to powder coating
- Time Consuming, as painting need dry, it takes longer time compared to powder coating
- Environmental impact
- It needs skill and expertise
Ideal applications for painting: Art and Creativity, Home and Interior Decoration,Automotive Industry, Consumer electronics, Furniture and Cabinetry,Signage and Advertising, and many others.
What is Powder Coating?
Powder coating refers to the process of electrostatically applying dry, finely ground colored coating resin particles onto a surface. The particles are charged using a spray gun to adhere to the surface. Excess powder is then removed, and the coated object is baked in an oven.
Adhesion: Powder coating relies on electrostatic attraction and heat to form a strong bond between the powder and the surface.
Surface Finish: Powder coating provides a durable and attractive surface finish with a smooth, even appearance. It offers a variety of colors and finishes, including textures and metallic options.
Thickness: Powder coatings are typically thicker than traditional liquid coatings, ranging from 20 to 200 micrometers.
Curing: The coated object is baked at high temperatures, usually around 200-220°C (390-430°F), melting the powder particles and fusing them into a continuous film.
Environmental Impact: Powder coating is considered more environmentally friendly than traditional coating methods. Excess powder can be reused, resulting in lower VOC emissions and less waste generated.
Advantages：
- Environmental friendliness
- Durabilityand long lasting
- Cost effective for large volume parts
- Much faster compared to painting, the setup time is longer.
Disadvantages：
- Compared to painting, it has limited colors
- Higher setup cost than painting
- It needs proper surface preparation
- Difficult to repair if any flaws
Ideal application for powder coating:Architectural and Construction,Outdoor Furniture and Appliances,Industrial Equipment and Machinery,Healthcare and Laboratory Equipment,Retail Displays and Fixtures
In conclusion, both painting and powder coating are effective methods for adding protection and enhancing the appearance of various surfaces. When choosing between painting and powder coating, it is essential to consider factors such as the desired finish, application method, durability, environmental impact, and specific requirements of the project.
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]]>Surface Finishes for CNC Machined Parts
The first impression of any CNC machined part lies in its external appearance and visual representation to onlookers. This crucial aspect has led modern industrialists and manufacturers to prioritize the aesthetics and functionality of their products.
To achieve the desired aesthetic appearance, manufacturers turn to surface finishing treatments for their CNC-machined parts. Surface finishing is a comprehensive and effective process that eliminates outer remnants, scars, threads, blurs, and any unaesthetic marks from the surface of the products.
By employing surface finishing techniques, manufacturers can greatly enhance the overall quality and appeal of their CNC-machined parts. The treatments not only remove imperfections but also provide additional benefits such as improved durability, resistance to corrosion, and enhanced performance.
In this article, we aim to provide you with an overview of common surface finishes available for CNC machined parts.
Varieties of CNC Machining Surface Finishes
Some manufacturers need extreme surface finishing, and the rest require very little. Keeping this point in mind, there are three categories of surface finishing for CNC-machined parts. Find out which one is suitable for your expectations and appeals to your customers.
1. As Machined Surface Finishes
Machining finishing is a very affordable option for manufacturers because it does not incur any extra cost due to being done by a CNC machine.
This surface finish is counted in terms of the Ra factor, which is the surface roughness that is defined as the deviation of a machined profile from the ideal surface.
Ra is the foundation of the calculation of surface finish, surface integrity, waviness, and flatness. Some ideal values of Ra are 3.2, 1.6, 1.8, and 0.8 micrometers. The lower the value of Ra, the higher the dimensional accuracy or tolerances.
Machining finishing is the best for those who have a tighter budget. However, it keeps the surface of CNC-machined parts filled with tool marks. In this way, it is not perfect for high-value projects.
2. Chemical Surface Finishes
Coating the surface of CNC-machined parts with another material is termed “chemical finishing. We can say that it is an extra layer of protection against abrasion, corrosion, and external factors.
Chemical finishing offers an aesthetic appeal to the parts because of the addition of their colour, shine, and other similar attributes. Discuss some of its types.
Anodizing
Anodizing is a phenomenon in which the immersion of a part in an electrolyte solution results in the formation of a protective sheath of oxide on the surface. Anodizing sheaths fall into two categories on the basis of applications.
Type I anodizing (up to 25 microns) is perfect for decorative and aesthetic purposes. While Type II anodizing (25 to 150 microns) is great for providing resistance against corrosion and abrasion to the material due to its thick oxide layering.
Alodine Coating
Alodine means a chromate layer, and alodine coating implies the implementation of a chromate thin coating on the CNC machined parts’ surface to boost their capability against corrosion, heat, and adhesion, resulting in an improvement in their longevity and durability. It works very well for aluminum and non-ferrous components.
Black Oxide Coating
Black oxide coating is a surface finishing process in which a black oxide coating is applied to the surface of CNC machined parts throughout for shielding against different contaminants and physical damages.
It improves the capacity to battle corrosion, offers wear resistance, and offers high lubricity. This surface finishing is the best option for steel, copper, and other alloys that form well-bonded bonds with oxygen molecules.
Electroplating Surface Finishes
Electroplating consists of two words: electric and plating. It involves the deposition of a metallic sheath throughout the surface of a part with the help of passing electricity to reach its melting temperature.
Electroplating is a very effective protection for the workpiece and protects the inner components from all kinds of contaminants and corrosive impacts.
3. Mechanical Surface Finishes
Under mechanical finishes, workpiece undergo multiple cycles of stresses and abrasions with corresponding treatments to obtain a smooth surface on the final products. See its types below.
Bead Blasting
Bead blasting involves the bombardment of spherical beads of glass or ceramic on the surface of CNC machined parts to get their textured, matte surface finish, eliminate imperfections, and create their uniform appearance.
Powder Coating
Attempt to layer a waxy powder on the surface of a part to make it durable and receive its versatile performance. Such powder coats are capable of resisting scratches and chips and do not become obsolete over time.
Brushing
It is a kind of surface treatment, rather than surface finishing. It harnesses a metal-wired brush or an abrasive pad to clean the surface and physically throw out all contaminants or particles on the surface of the parts.
Painting
The use of lacquer and polyurethane in their liquid form to apply over the surface of CNC machined parts to protect the surface from exposure to water, contaminants, dirt, and atmospheric irregularities is known as painting.
Painting CNC surface finishing is a great option to improve the lifespan by keeping corrosion and abrasion at bay by covering the whole external body of a part.
In conclusion, surface finishes for CNC machined parts are instrumental in achieving the desired quality, functionality, and aesthetics. By utilizing the appropriate surface finishing techniques, manufacturers can enhance the performance, durability, and overall value of their CNC machined components.
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]]>Surface finishes options for metal 3D Prints
Metal 3D printing has completely revolutionized the manufacturing industry by enabling the rapid and cost-effective production of complex metal parts.
However, the inherent nature of the metal 3D printing process often results in surfaces that may require additional treatment to achieve the desired aesthetics, functionality, and performance. This is where surface finishing becomes crucial.
In this article, we will explore various surface finishes specifically tailored for metal 3D prints. These techniques not only improve the appearance but also enhance the mechanical performance, surface quality, and suitability for specific applications.
As-Printed Finish:
This type of surface typically has visible layer lines and some traces resulting from the removal of supports. The roughness is RA7. However, even without surface treatment, it does not affect the accuracy of the part. This surface finish is also a good choice for parts that require secondary processing.
Machined Finish:
For parts that require high precision, secondary machining is necessary. The highest achievable precision is +/- 0.02mm. For parts that require this type of post-processing, it is essential to leave enough cutting allowance before printing. After the post-processing, the printed parts can achieve the normal precision and surface smoothness of CNC machining. It also opens up possibilities for other additional post-processing techniques.
Media Blasting surface finishes:
Media blasting used in metal 3d printing, is a highly effective method that utilizes compressed air to propel blast media, such as alumina, stainless steel shot, metal powder, or glass beads, onto a part’s surface. This process helps wear down the surface and achieve a uniform matte or shiny finish.
It is particularly advantageous for tasks like removing discoloration, blending surface scratches, and mitigating tool marks. Importantly, media blasting does not compromise the dimensional accuracy of parts and can be completed in just a matter of minutes.
The media blasting process’s aggressiveness can be tailored by adjusting the air pressure. Lower pressures are suitable for altering the surface color of a part, while higher pressures with steel shot or glass beads can effectively deburr the surface, enhancing its smoothness and overall appearance.
Glass bead blasted surface. It results in a satin and uniform finish.
Chemical Surface Treatment:
Chemical treatments such as etching or passivation can be used to alter the surface finish of metal 3D printed parts. These treatments can remove impurities, improve corrosion resistance, or create specific textured patterns on the surface.
However, before carrying out such surface treatments, it is necessary to polish and sand the surface of the samples to increase their durability.
Electropolishing
Electropolishing is an ideal solution for polishing irregularly-shaped objects, the process reduces surface roughness, levels micro-peaks and valleys and dramatically improves surface finish.
Electroplating is a process in which an electric current is employed to attract positively-charged metal ions, dissolved in a solution, towards a negatively-charged part. This results in the formation of a thin metal coating that covers the entire surface of the part.
Allegheny Image Source
Anodizing, painting:
Similar to CNC machining, these processes are also applicable to metal printed parts. However, compared to CNC machining, the surface finish of metal printed parts is generally poorer. If direct oxidation or painting processes are applied, the color of the finished parts may appear inconsistent, and visible lines or pits may be present. Therefore, some post-processing is required before performing such treatments.
For parts with less demanding surface requirements, bead blasting and tumbling can be performed on the samples. For parts with higher surface quality requirements, fine polishing and polishing treatments can be carried out.
Tumbling:
This process is very similar to traditional polishing techniques used in jade and jewelry making. The equipment principles and materials used are nearly identical. When determining whether a sample requires tumbling, the most important factor is to observe if there are delicate details on the surface that could be easily damaged, such as threads or thin-walled structures. In such cases, caution should be exercised when using this process.
The main material used in tumbling is small stones with triangular edges, along with some incremental additives. After undergoing tumbling, the surface of the samples appears shiny and polished.
Manual polishing:
Due to its flexible and simple operation, as well as low equipment requirements, it is the most traditional but also the most effective and widely used polishing method. Commonly used metal polishing tools include metal polishing buffing wheels, grinding stones, sanding bands polishers, rotary polishers, rotating belt wheels, and so on. It is necessary to pay attention to the intensity of polishing to avoid compromising precision and surface effects.
It’s important to note that the specific surface finishes achievable with metal 3D printing may vary depending on the printing technology used (e.g., selective laser melting, electron beam melting, binder jetting) and the type of metal being printed. Additionally, post-processing techniques can be combined or customized to achieve specific surface requirements based on the desired application or aesthetics of the part.
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]]>Guide for surface roughness
Definition
The Arithmetic Average Roughness, noted as Ra, is the absolute average relative to the base length.
For simplicity, the Ra value indicates the average surface roughness for the length of the measurement performed, i.e., the average difference between peaks and valleys.
To schematize what roughness is, we can imagine a two-dimensional cut of the surface. The higher the roughness of this surface, the greater the difference between the peaks and valleys of the surface.
The roughness Ra is an excellent way to quickly check that the surface corresponds well to the customer’s request, its value is representative of the general condition of the surface.
Why is Surface Roughness So Important in Manufacturing?
You can see a visual comparison of surfaces with different roughness values in the image below. In addition to changing the look, roughness plays a key role in contact mechanics since higher roughness values increase friction and cause faster wear on components. More roughness also means more surface irregularities that can become nucleation sites for corrosion and cracks. Still, higher values of roughness aren’t necessarily bad; when you’re interested in adhesion, roughness can be a benefit if you choose an appropriate material and surface finishing option.
How to Measure Surface Roughness
There are several measuring systems for surface roughness. The systems include:
The direct measurement methods measure surface roughness using a stylus. That involves drawing the stylus perpendicular to the surface. The machinist then uses a registered profile to determine roughness parameters.
Non-contact methods involve the use of light or sound instead. Optical instruments like white light and confocal replace the stylus. These instruments use different principles for measurement. The physical probes can then be switched with optical sensors or microscopes.
First, the instrument used will send an ultrasonic pulse to the surface. Then, there’ll be altering and reflection of the sound waves back to the device. You can then assess the reflected waves to determine roughness parameters.
Comparison techniques employ surface roughness samples. These samples are generated by the equipment or process. Then, the manufacturer uses tactile and visual senses to compare the results against the surface of known roughness parameters.
An example of in-process techniques is inductance. This method helps to evaluate surface roughness using magnetic materials. The inductance pickup uses electromagnetic energy to gauge the distance to the surface. Then, the parametric value determined can help find out comparative roughness parameters.
Conclusion
Since getting precise surface roughness will be expensive and challenging in today’s manufacturing, surface finishing operations require the finest strategy to generate desired finishes on fabricated parts.
At IN3DTEC, we offer full dimensional inspection reports, so you can be sure of desired results. We also offer different finishing processes ranging from anodizing, electroplating, bead blasting to polishing, brushing, and more. We are always ready to provide the best service for you.
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]]>Electroplating Vs Physical Vapor Deposition (PVD) Coating
What is Electroplating?
The tool is placed inside a liquid solution and connected to a cathode, or negative pole of a power supply (think negative wire to a car battery). The material you wish to coat the tool with is connected to the anode, or positive pole, and placed in the solution, too.
The negatively charged tool attracts ions from the positively charged coating material, and a layer of coating is formed. The tool is left in the solution long enough to attract the desired thickness of coating, then removed. The longer the tool is left in, the thicker the coating.
Popular coating materials include chrome, gold, silver, nickel, and copper. It should be noted that these materials can, and in many cases should, be applied in several layers depending on the material your tool is made of. For instance… if you have a silver tool, you’ll likely want to coat it with copper and nickel to give it the proper strength.
You can not plate certain materials like titanium, aluminum or polymers with electroplating.
That leads us to PVD.
What is Physical Vapor Deposition?
PVD coating is a process whereby the tool is placed in a vacuum chamber with the coating material. The coating material is then vaporized and applied to the tool as a coating. To ensure the tool is completely coated, it is rotated and repositioned during the PVD process.
What’s unique about PVD is that the coating becomes part of the mold. Where most mold coatings crack or wear with time, PVD mold coatings form an atomic bond with the tool that can’t easily be broken.
Compared to electroplating, PVD coatings have improved scratch and wear resistance, more color options, a cleaner, safer process, and offer the option of use after electroplating for wear-resistance and aesthetics. The process requires complex machines and skilled operators, which means a higher cost. Besides, it has a relatively slow operating speed.
If you want to learn more or finish your parts with PVD coating finish, please contact IN3DTEC for more information.
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]]>The post VaporFuse Surfacing – an enhanced post treatment for your 3D parts appeared first on IN3DTEC | Prototyping & On-demand manufacturing services.
]]>VaporFuse Surfacing an enhanced post-treatment for your 3D parts
With the constant growth of Additive Manufacturing and its fields of application, the demand for 3D-printed parts is also increasing.
Today, market-ready products manufactured with Powder Bed Fusion technologies such as Selective Laser Sintering (SLS) or Multi Jet Fusion (MJF) must meet both aesthetic and functional requirements. These requirements can vary depending on the product, industry, and application. Since Powder Bed Fusion technologies work layer by layer, the outcome is parted with rough surfaces compared to conventional manufacturing methods. Good post-processing helps to change these part properties.
While for example, tumbling as an abrasive method for 3D-printed parts is usually counterproductive because the material is removed.
Vaporfuse surfacing achieves smooth parts without compromising the part’s geometry or mechanical properties. The surface imperfections are erased from parts with no line of sight issues and effectively seal even complex geometries with internal cavities.
The process of Vaporfuse surfacing
First, The 3D Prints are suspended in the processing chamber and exposed to a controlled amount of solvent vapor. The vapor condenses on the parts, interacting with the polymers at the surface and causing the surface to re-flow.
After a time, the machine heats back up, causing the solvent to re-vaporize, and then it is extracted from the parts and the processing chamber. The parts are then thoroughly dried in the processing chamber, leaving behind just a newly smoothed surface.
The enhanced properties of vaporfuse surfacing
VaporFuse Surfacing is a green industrial technology that delivers sealed and smooth surfaces with improved airtightness, bacteria protection, and part strength. During the process, the surface roughness is reduced to a minimum. The technology is suitable for finishing parts made with laser sintering (SLS), HP Multi Jet Fusion(MJF), and other technologies such as (FDM). It is compatible with many materials, from tough PA12 to TPU and other soft materials.
So what are the advantages of Vapor smoothing?
Sealed surfaces: roughness is reduced by up to over 80%, both inside and outside. It results in a better flow of water and air in each piece.
Productive spray painting: VaporFuse replaces the priming step and reduces the time and material required down to a third.
Improved airtightness: Parts with a skinny layer thickness become airtight due to VaporFuse, allowing more design freedom and using less manufacturing material.
Reduced friction: Using VaporFuse Surfacing technology can create smooth parts with over 40% less friction, less abrasion, and no chafing effect.
Improved stability: Printed parts with greater flexibility & reduced embrittlement.
Bacteria inhibition: VFS protects surfaces from bacterial growth, making them easier to clean and disinfect. That leads to washable surfaces, resistance to chemical and oily products, and avoiding residues after cleaning the parts.
A green industrial solution
Until now, chemical smoothing was mainly linked to aggressive chemicals that can generate toxic waste, having a harmful impact on the ecological footprint, but also might be potentially damaging for operators, as they were CMR solvents (carcinogens, mutagens, and reprotoxic). Therefore, the invention of a sustainable post-processing solution was necessary.
The solvent for vaporfuse surfacing is a non-CMR solvent, eco-friendly.
In addition, the system does not produce waste due to a completely closed circuit with the integrated recovery of the solvent. The system can operate autonomously 24 hours a day, seven days a week, and is applicable for Industry 4.0.
If you are interested in vaporfusing surfacing, please get in touch with IN3DTEC. We warmly welcome your question or inquiry!
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