The effect of machining parameters on the surface quality of 3D printed and cast polyamide

Fused deposition modeling (FDM) is an additive manufacturing (AM) technique that has emerged as a suitable application in different areas, including machine design and manufacturing. The main advantages of this method over conventional methods include that it is faster and produces less material waste. Besides, AM offers computer-aided design and manufacturing but does not include any limitations on the product's geometry and does not require any extra tools. End milling is a conventional manufacturing process used for profiling, slotting, and facing. In this study, at the point of overcoming the weaknesses of AM surface quality, it was investigated whether the cast polymer's surface quality could be reached with hybrid manufacturing (AM + milling). For this reason, the parts produced by FDM were subjected to end milling, and the effect of cutting depth, feed rate, and rotation speed on surface quality and chip type were investigated. The results obtained are compared with the results of the milling operation of cast polyamide. For all results, surface quality increases with a rising feed rate. In general, the surface quality obtained by milling parts produced using FDM is low, but each manufacturing technique is affected differently by the end milling conditions. Low rotation speed and high feed rates should be preferred to obtain the desired surface quality from FDM printed polyamide parts.