BATAAN PENINSULA STATE UNIVERSITY

College of Engineering and Architecture

Department of Industrial Engineering

DESIGN OPTIMIZATION OF DR3AM VAPOR POLISHING DEVICE FOR ABS 3D-

PRINTED PARTS

In partial fulfillment of the requirements for the degree of

BACHELOR OF SCIENCE IN INDUSTRIAL ENGINEERING

for the course IECP 0421 IE CAPSTONE PROJECT 2

Baluyut, Rosa Mae D.

Bartolome, Jan Rapaela B.

De Guzman, H. Romel B.

Morales, Josefa L.

Moscosa, Anthony N.

Olavides, Angeline D.

Sanchez, Jan Aubrey B.

June 2023

APPROVAL SHEET

i
This is to certify that we have supervised the preparation of and read the IE capstone
study prepared by Rosa Mae D. Baluyut, Jan Rapaela B. Bartolome, H. Romel B. De
Guzman, Josefa L. Morales, Anthony N. Moscosa, Angeline D. Olavides, Jan
Aubrey B. Sanchez entitled Design Optimization of DR3AM Vapor Polishing Device
for ABS 3D-Printed Partsand that the said feasibility/project study or research report
has been submitted for final examination by the Oral Examination Committee.

Engr. Brian J. Tuazon Engr. Michaela T. Espino

Technical Adviser IE Capstone Project Adviser

As members of the Oral Examination Committee, we certify that we have examined this
IE capstone study, presented before the committee on June 07, 2023, and hereby
recommend that it be accepted as fulfillment of the feasibility/project study or research
report requirement for the degree in Bachelor of Science in Industrial Engineering.

Ray Noel M. Delda, MSc Engr. Ciara Catherine L. Gache

External Panel Panel Member

This project study or research report is hereby approved and accepted by the Bataan
Peninsula State University-Main Campus as a fulfillment of the feasibility/project
study or research report requirement for the degree in Bachelor of Science in Industrial
Engineering.

Engr. Ruevan E. Alboro Engr. Faye L. Baret

IE Department Chairperson College Dean

TRANSMITTAL LETTER

ii
June 09, 2023

Engr. Michaela T. Espino

Instructor
Department of Industrial Engineering
College of Engineering and Architecture
Bataan Peninsula State University
Balanga City, 2100 Philippines

Dear Madam:

In partial fulfillment of the subject IECP0421 (Capstone) and per your guidance and
instruction, we are submitting this project study to you.

The project study includes the study's background, significance, objectives, design
procedures, and design concept considerations.

This study ought to comply with the standards and receive the utmost consideration you
require.

Sincerely,
Baluyut, Rosa Mae D.
Bartolome, Jan Rapaela B.
De Guzman, H. Romel B.
Morales, Josefa L.
Moscosa, Anthony N.
Olavides, Angeline D.
Sanchez, Jan Aubrey B.

iii
 TABLE OF CONTENTS

TITLE PAGE ………………………………………………………………………...i

APPROVAL SHEET …………………………………………………………………ii

TRANSMITTAL LETTER …………………………………………………………...iii

TABLE OF CONTENTS ……………………………………………………………...iv

LIST OF TABLES ……………………………………………………………………..vii

LIST OF FIGURES …………………………………………………………………….viii

NOMENCLATURE ……………………………………………………………………..x

ABSTRACT ……………………………………………………………………………..xi

Chapter 1: THE PROBLEM AND ITS BACKGROUND

1.1 Introduction……………………………………………………………1

1.2.Background of the Study……………………………………………...4

1.3.Statement of the Problem……………………………………………...4

1.4 Significanceof thestudy……………………………………………….6

1.5 Objectivesof the Study………………………………………………...7

1.6 Scopeand Limitation…………………………………………………..7

Chapter 2: REVIEW OF RELATED LITERATURE

2.1 Related Literature…………………………………………….........…9

2.2Fused Filament Fabrication ……………………...…………………...11

2.3 AcrylonitrileButadieneStyrene……………………………………...11

2.4 Post-Processing…………………………………………………........12

iv
 2.5Vapor Polishing…………………………………………………........13

2.6 Related Studies……………………………………………………….14

2.7 Definition of Terms……………………………………………..........18

Chapter 3: CONCEPTUAL FRAMEWORK………………………………………..19

3.1 Independent Variable…………………………………………….......24

3.2Dependent Variable…………………………………………………..24

3.3Engineering Theories Applied………………………………………..25

Chapter 4: METHODOLOGY

4.1 Methodological Framework…………………………………….……28

4.2Data Collection………………………………………………….........29

4.3 Design Preparation………………………………………………...…29

4.4 Materials and Optimization…………………………………………..29

4.5Testing and Evaluation…………………………………………….....33

4.6Time Study of Acetone Evaporation………………………………….37

4.7 Consumption Study………………………………………………......37

Chapter 5: RESULTS AND DISCUSSION

5.1 Effectiveness of the Optimized Vapor Polishing Device……………38

5.2 Dimensional Accuracy……………………………………………….39

5.3 Surface Roughness……………………………………………….…..41

5.4Tensile Strength……………………………………………………....42

5.5 Impact Test………………………………………………..……….…44

v
 5.6Time Study of Acetone Evaporation………………………...……..…46

5.7 Consumption Study…………………………………………………..47

Chapter 6: CONCLUSION AND RECOMMENDATION……….….…….………..49

MISCELLANEOUS PAGES

Acknowledgement……………………………………………………….52

References……………………………………………………..…………54

Curriculum Vitae……………………………………………………….. 65

Originality Report………………………………………………………..73

LIST OF TABLES

vi
TABLE 5.1: Advantages and Disadvantages of Different Modules……………………..38

TABLE 5.2: Summary of dimensional changes for Unpolished and Polished cubes
……………………………………………………………………………………………40

TABLE 5.3:Results obtained by Mountains9 Topography Software……………………41

TABLE 5.4: Tensile Strength and Young's Modulus of Unpolished and Polished
Specimens……………………………………………………………………..…………42

TABLE 5.5: Summary of Mean Experimental Results of Impact Test………………….44

TABLE 5.6: Time Study for Acetone Evaporation……………………………………..46

TABLE 5.7:Consumption Study in Correspondence with Testing and Experiments…..47

LIST OF FIGURES

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FIGURES 3.1: The Paradigm of Study…………………………………………………..19

FIGURES 3.2: Flowchart of Investigation on the Effects of Acetone Vapor-Polishing to

Fracture Behavior of ABS Printed Materials at Different Operating Temperature (Tuazon

et. al, 20220)…………………………………………………………………………......21

FIGURES 3.3: Flowchart of Fabrication and Testing of a Vapor Polishing Device of ABS

3D-Printed Parts (Gache et. al, 2022)……………………………………………………22

FIGURES 3.4: Optimized Vapor Polishing Device Process Flowchart…………………23

FIGURES 4.1.1: Process Flow Chart……………………………………………………28

FIGURES 4.4.1: CAD Model of the Previous Vapor Polishing Device Using Mist Maker

(Fabrication and Testing of a Vapor Polishing Device for ABS 3D-Printed Parts, Gache

et. al, 2022)………………………………………………………………………………30

FIGURES 4.4.2: CAD Model of the Optimized Vapor Polishing Device………………31

FIGURES 4.4.3: CAD Model of the Final Design for Optimized Vapor Polishing Device

……………………………………………………………………………………………31

FIGURES 4.4.4: Optimized Vapor Polishing Device Final Design Construction………32

FIGURES 4.5.1: Cube Specimen Measurement…………………………………………34

FIGURES 4.5.2: Surface Roughness Digital Topography of 10mm cube………………35

FIGURES 4.5.3: Tensile Test Set-up and Tensile Specimen’s Dimension……………...36

FIGURES 4.5.4: Actual Impact Testing Arrangement…………………………………..37

FIGURES 5.1: Images of (a) Unpolished Cube Specimens (b) Polished Cube Specimens

……………………………………………………………………………………………39

viii
FIGURES 5.2: Digital Image of (a) Unpolished and (b) Polished Surface of 10x10 Cube

Specimen…………………………………………………………………………………41

FIGURES 5.3: (a) Unpolished and (b) Polished Type IV Tensile Specimen …………...43

FIGURES 5.4: Summary of (a) Stress–Strain Curve and (b) Young’s Modulus of

Unpolished and Polished Type IV Test Specimens……………………………………...43

FIGURE 5.5: Unpolished (a) and Polished (b) Izod Type E Specimen…………………45

FIGURES 5.6: Summary of (a) Impact Resistance and (b) Impact Energy of Unpolished

and Polished Izod Type E Specimen …………………………………….……………..46

ix
 NOMENCLATURE

Volume Reduction Formula (1):

Volume Unpolished- Volume Polished

Volume Reduction (%) = ×100%
Volume Unpolished

Impact Resistance/Impact Energy Formula(2): Impact Resistance, I R = ES

(1)
w

Impact Energy, ES
(2) IE =
dw

x
 ABSTRACT

3D printing is an additive manufacturing method that turns digital design into an actual
product. 3D printing requires post-processing. Acetone vapor polishing proved highly
beneficial in smoothing ABS 3D-printed parts with substantial variations within the
initial and final viewpoints. Generally, the acetone polishing process utilizes an
improvised method; mist maker. For a systematic post-processing method, constructing
an optimized vapor polishing device using heat is conducted in this study. The
researchers exploit dimensional accuracy, surface roughness, tensile strength, and impact
tests for better experimentation. The dimensional accuracy of the 3D-printed sample was
measured using Digital Vernier Caliper. Then, AMScope MU503 and Mountains9
Topography software for apprehending the surface roughness. The tensile test utilizes
Shimadzu AGS-X Series Universal Testing Machine with 10kN capacity. ASTM D256
test method E for impact test. The findings indicate the smoothness of 3D-printed parts
surface after vapor polishing without altering its physical geometry. The tensile test
reveals that the overall elasticity of the 3D-printed Type IV tensile specimen has
increased significantly. The Impact test shows the specimen's capacity to sustain a
resistive impact from a swinging pendulum, which indicates that post-processing using
the optimized vapor polishing device significantly affects the overall mechanical
properties of the 3D-printed specimen.

xi
 CHAPTER I

THE PROBLEM AND ITS BACKGROUND

This chapter presents the Introduction, Background of the Study, Statement of the

Problem, Significance of the Study, Objectives of the Study, and Scope and Limitations

of the Study.

Introduction

3D printing is becoming known globally. It was used to manufacture various

products or objects we could not typically obtain elsewhere and was made layer by layer.

As Kerr (2022) mentioned, FDM 3D printing is analogous to using a computer-controlled

hot glue gun in its most basic form. In contrast to traditional hot glue guns, 3D printers

have a nozzle that is only 400 microns (0.4 mm) in diameter. FDM 3D printers, instead of

ejecting a cylinder of hot glue, release a thin strand of molten "thermoplastic," which is

simply a plastic designed to melt at a particular temperature, usually around 200-250 °C.

According to Dizon et al. (2020), Fused Deposition Modelling (FDM) technology

is one of today's most popular 3D printing techniques. The reason for its demand is its

low cost but high printing speed. However, post-processing is required for this

technology to improve layer adhesion strength and surface finish. Heat treatment and

vapor-polishing are post-processing techniques used to improve these issues. Heat

treatment is a post-fabrication that enhances the mechanical properties of 3D-printed

polymers. Balancing the internal thermal stresses can reduce layer adhesion and thermal

stresses, resulting in improved mechanical properties of thermoplastic polymer parts

(Zapciu et al., 2021). Vapor polishing is another way to improve the properties of a 3D-

1
printed polymer part. This is a process wherein the surface of the printed part is

smoothened through the use of vapor from solvents to melt the surface. This process

allows the printed part to be in contact with the fumes, placing it on a higher chemical

bath surface. It was carefully closed and given a standard time to smooth any rough

surface without causing any shape alteration (AMFG, 2017).

There are different variations of 3D filaments used in Additive Manufacturing

(AM). As stated by Mhatre (2022), the common types are PLA (polylactic acid), ABS

(acrylonitrile butadiene styrene), PETG (polyethylene terephthalate glycol),

TPE/TPU/TPC (thermoplastic elastomer/polyurethane/copolyester), ASA (acrylonitrile

styrene acrylate), PA (polyamide or nylon) and PC (polycarbonate). With the different

types of 3D filaments, the main focus of this study is the post-processing of ABS filament

parts. ABS is a thermoplastic polymer that has achieved great success in engineering

applications and acquired high performance. ABS has desirable properties as an ideal

material for various applications, including its mechanical strength and chemical

resistance (Saude et al., 2018). However, poor layer bond strength and rough surface

consistency are common characteristics of FDM 3D-printed materials that require post-

treatment. Heat treatment and vapor-polishing are procedures that are designed to

improve 3D-printed materials' poor layer adhesion and rough surface finish. According to

Carolo et al. (2022), acetone is a colorless, extremely volatile liquefied chemical used for

cleaning parts. The high reactivity of acetone with ABS filament parts causes the topmost

layer of ABS to dissolve and leave a smooth finish (AMFG, 2017). The smoothing

process can be difficult to control, so there would be inaccuracy in dimension and minor

details. Since this solvent is highly volatile and flammable and considered a hazard, it is

2
advisable to be handled with the utmost care, by storing it at cool temperatures and

distant from intense sunlight and heat sources (Carolo et al., 2022).

This study will also focus on the acetone evaporation of the device by using the

Insulated Nichrome Coil. The Insulated Nichrome Coil is a core heating element that is

commonly used in various industrial and scientific applications. This type of metal is

highly resistive, with voltage current applied to the coil which produces heat. It is highly

resistive even with exposure to a small amount of electrical current it can heat up.

Nichrome is a resistance metal alloy that is a chromium-based heating alloy with

excellent resistance to heat, corrosion, and water oxidation at elevated temperatures up to

1400 °C (Razmi et al., 2020).

Additionally, it will focus on creating a new base for the vapor polishing device

using aluminum The type of aluminum used in this study is T6 6061 aluminum grade.

According to Spira (2021), aluminum 6061 is one of the strongest alloys on the market. It

is highly corrosion-resistant and a strong material that can be used to make lightweight

products and components, making it ideal for use in various structural components,

welding, machines, electronics, and industrial goods applications. The T6 label specifies

the range of hardness or temper. It has an excellent strength-to-weight ratio and can be

heat-treated to achieve higher strength. With this being said, it is also widely used for

engineering, structural, etc., because of its capacity to be formed and welded. Before

choosing a material, Pekar (2020) contends that it is necessary to investigate the

compatibility of fluids and component materials. Extensive tests on loop heat pipes that

have been done to determine compatibility data empirically confirmed that acetone is

compatible with aluminum, stainless steel, copper, and brass.

3
Background of the Study

This study aims to optimize the existing vapor polishing device for ABS 3D-

printed parts in the DR3AM Center. According to Gache et al. (2022), the device's design

should be optimized. For instance, the wooden cover of the device can expand and be

affected by the chemical reagent acetone. The mist maker of the vapor polishing device is

of poor quality.

In this study, the researchers aim to optimize the vapor polishing device as the

overall set-up of the system for the acetone vapor bath can be optimized to be more

efficient. The wooden cover of the device will be replaced with aluminum to prevent

deformation. The researchers will use an insulated nichrome coil instead of a mist maker

to make the acetone evaporation process more effective and for a longer lifespan of the

device.

In addition to the optimization, additional test experiments will be done in this

study to determine further the average temperature of insulated nichrome coil to achieve

smooth acetone evaporation, the standard volume of acetone, and the time required for

vapor polishing of 3D-printed parts. The researchers decided to install a digital

thermostat temperature alarm and time relay module for a better system function.

Statement of the Problem

The general problem of this study is: How can the optimization in the vapor

polishing device be utilized to achieve efficiency in the acetone vapor polishing of the

ABS 3D-printed parts?

Specifically, this study seeks to answer the following questions:

4
1. What are the problems and factors affecting the function and quality of the vapor

polishing device?

1.1. The wooden cover of the device can contract and is susceptible to the

chemical agent acetone.

1.2. The mist maker of the vapor polishing device is of poor quality.

2. What are the essential improvements needed to achieve the total efficiency of the

vapor polishing device?

2.1. The wooden cover will be replaced with aluminum to avoid

deformation.

2.2. The researchers opted to apply heat and use an insulated nichrome

coil instead of a mist maker to improve the acetone evaporation efficiency

and make the device lifespan longer with a digital thermostat temperature

and time relay module to improve device performance.

3. Is using an insulated nichrome coil effective in terms of:

3.1 Dimensional Accuracy

3.2 Surface Roughness

3.3 Tensile Strength

3.4 Impact Test

4. What is the average temperature of the insulated nichrome coil to achieve smooth

acetone evaporation, the standard acetone volume, and the time required for the

vapor polishing of each 3D-printed part?

5
Significance of the Study

This study is undertaken to improve the existing acetone vapor polishing system

for ABS 3D-printed parts. The findings of the study will be highly beneficial for the

following sectors:

3D Printing Laboratories. The study will provide a long-term usage of acetone vapor

polishing that will make it more practical and simpler to use while also being more

successful at retaining the value of the 3D-printed items. Additionally, it will lower the

costs associated with equipment maintenance.

BPSU-DR3AM Center. The upcoming study will enhance the procedure or the

experience of polishing the 3D-printed components produced and designed at BPSU.

Thus, it will be more favorable when more 3D-printed materials are made and are under a

polishing process.

Other Universities. The device and information will be a reference in studying polished

3D-printed parts and identifying the most suitable approach in vapor polishing. The data

presented will also serve as an introduction to the school that will establish 3D printing

laboratories.

Students. The device and findings of the study will lead them to gain interest in 3D

printing, as well as encourage them to experience how acetone vapor polishing of 3D-

printed objects was done. They will also benefit from the device's convenience for their

future activities.

Future Researchers. The study findings will provide information on the efficiency of an

improved vapor polishing method in 3D-printed products. It will serve as the foundation

for additional studies that intend to put some interest in acetone vapor polishing.

6
Objectives of the Study

General Objective

The general objective of the study is to improve the performance of the existing

vapor polishing device for ABS 3D-printed parts in the DR3AM Center.

Specific Objectives

 To introduce a more efficient alternative method for the vapor polishing process

by using an insulated nichrome coil instead of a mist maker.

 To increase the durability of the device by replacing other parts with aluminum

material.

 To identify the average temperature of the insulated nichrome coil to achieve

smooth acetone evaporation, the standard volume of acetone, and the time

required for the vapor polishing of 3D-printed parts.

Scope and Limitations of the Study

The focus of this study is to optimize the existing vapor polishing device at the

DR3AM Center by using an insulated nichrome coil to reach a specific temperature that

can help accelerate the acetone vapor polishing time. This method can help acetone to

vaporize gradually, making the polishing process of the 3D-printed specimen to become

more efficient. The researchers also replace the wooden cover with aluminum to avoid a

reaction from the chemical reagent acetone. In this study, the researcher expands the

material testing procedures to comprehensively analyze the effect of post-processing

procedures on the material's physical properties and to identify the average temperature

7
of insulated nichrome coil to achieve smooth acetone evaporation, the standard volume of

acetone and the time needed for the vapor polishing of 3D-printed parts.

8
 CHAPTER II

REVIEW OF RELATED STUDIES AND LITERATURE

This chapter presents an overview of various related literature and studies in

reference to this research. The studies mentioned below are further described in the

opening paragraph, followed by a second statement that sets out the importance of these

studies in this paper.

Related Literature

3D printing, also called Additive Manufacturing (AM), is a rapidly emerging

technology. 3D printing is widely used around the world nowadays. This technology is

widely used in agriculture, healthcare, automotive, etc. It is also used in the aerospace

industry to customize open-source designs (Shahrubudin et al., 2019). The technology

helps accommodate highly complex designs, reduce material waste, repair more

demanding damaged parts, and more (Rajaguru et al., 2019).

In the agricultural industry, instead of working manually to create tools to

produce goods and objects with practical use, additive manufacturing allows this

development by channeling our ideas from digital to tangible (Crisostomo and Dizon,

(2021). With this technology, we can save the time and money that might have been

spent on manufacturing processes, which can be time-consuming and complicated.

With the ongoing pandemic, additive manufacturing dramatically helps the

healthcare industry, and because of COVID-19, governments worldwide are working

together to address the problem. The possibility of a worldwide shortage of PPEs,

including masks, face shields, suits, and other clinical equipment, has raised worries

9
among healthcare professionals. With additive manufacturing, it proposes an opportunity

to create an alternative and immediate distribution method for personal protective

equipment (PPEs) and other medical devices (Dizon et al., 2020).

In the Automotive Industry, Additive Manufacturing has made substantial

progress and has proved effective in replacing components and materials manufactured

through traditional methods. In the automotive business, 3D printing has demonstrated its

efficacy. However, it still has to make a lot of advancements to maximize its potential as

a substitute for producing particular components and materials (Tuazon et al., 2021).

According to Martinez et al. (2020), the aerospace industry was the first to use

additive manufacturing, specifically three-dimensional printing (3D printing). 3D printing

was used in this industry to produce aircraft parts and components. The most commonly

used materials in aircraft prototypes are acrylonitrile butadiene styrene (ABS)

thermoplastic, carbon fiber, and thermoplastic composite. Nylon 12 is also one of the

common techniques used in this field using selective laser sintering, fused deposition

modeling, or composite filament co-extrusion technology.

The merging of additive manufacturing (AM) with robotics has resulted in

breakthroughs in the robotics industry via complex and cutting-edge additive

manufacturing (AM) techniques and components (Delda et al., 2021). Considering the

rise of additive manufacturing, new materials are being developed and tailored for

specialized needs. This research examines several materials for 3D printing merging

robotics. Because of their adaptability for robotic uses, they discovered compounds that

include polyethylene glycol diacrylate (PEGDA) as the most frequently used 3D-printed

components. The Acrylonitrile butadiene styrene (ABS), flexible photopolymers, and

10
elastomer-based materials were also discovered to be the most commonly utilized 3D

printing materials.

Additive manufacturing (AM) has been a rapidly growing topic in academia and

industry in recent years. The technology is constantly being explored and improved based

on significant advantages such as the ability to produce complicated shapes (Perez et al.,

2020). In addition, it is rapidly overcoming its limitations, so improvements to the AM

lead to better opportunities and applications in the future.

Fused Filament Fabrication (FFF)

Fused Filament Fabrication (FFF) is one of the standard 3D printing technologies.

It is also defined as FFF (Fused Filament Fabrication), which is widely used for its layer-

by-layer extrusion that does not cost a lot but with excellent production capacity

compared to other techniques (Tuazon et al., 2020).

According to Singh et al. (2020), with the easy fabrication process, accuracy, and

flexibility of materials of FDM printers, it is now widely used in manufacturing

technologies. This printer can meet current demand needs, generating complex

geometries instantly. FDM printers operate better with polymers, mainly amorphous ABS

(Mazzanti et al., 2019).

Acrylonitrile Butadiene Styrene (ABS)

ABS (Acrylonitrile Butadiene Styrene) is a common thermoplastic polymer with a

glass transition temperature of approximately 107 ℃. ABS will liquefy when heated to

their melting point, allowing them to be easily injection molded. When ABS is cooled

11
and reheated, there is no significant degradation which shows that it is a good candidate

for recycling (Tuazon et al., 2020).

According to Selvamani et al. (2019), it is agreed that ABS contributes to high

impact resistance, toughness, heat stability, resistant chemicals, and the flexibility to

conduct practical assessments on specimen parts. Besides that, relatively good strength

and acceptable thermal shrinkage are the additional values that widen the use of ABS in

FDM. These values allow possible post-processing (utilizing machining, coating, or

gluing) of the printed product using ABS. Even though ABS is beneficial in various ways

and has a higher value of certain mechanical properties, when it is applied in FDM,

researchers have proved that FDM parts or specimens experience an approximately 45%

decrease in modulus and a 30–60% reduction in final tensile strength determined by the

part orientations as compared to standard material elements.

Post-Processing

In additive manufacturing, the post-processing approach is used to improve the

surface finish of the 3D-printed parts and the parts' unwanted microstructure phases and

defects. Post-processing processes have been proven to improve the surface

characteristics and physical and mechanical properties of the 3D-printed part (Mahmood

et al., 2022). According to Dizon et al. (2021), typically, the process that takes a long

time in post-processing is the primary post-processing category. This primary category is

support, powder, or resin removal. It is also claimed that post-processing operations can

be by batch or serial processing, and it is also a manual, semi-automated, or automated

process.

12
 According to (Chohan & Singh, 2017), post-processing techniques are divided

into mechanical and chemical categories. Material removal, sanding or surface polishing,

gap filling, coating, and other mechanical finishing procedures are post-processing

examples (Dizon et al., 2021). While these are the most generally used finishing

procedures for various materials used in FFF printers, alternative processes are also

recommended depending on the materials used in printing. For instance, vapor polishing

is the most typical finishing method characterized as a chemical postprocessing treatment

used on ABS prints produced by built-in FFF printers. In addition, the acetone bath

technique is one of the most effective post-processing techniques, with the best

dimensional accuracy (Nsengimana et al., (2019).

Vapor Polishing

As stated by Neff et al. (2018), acetone vapor polishing is a technique for

eliminating some extraneous elements that detract from the visual appeal of 3D-printed

products. The "high" materials will flow into the "low" sections by their layer with the

assistance of surface tension. However, due to energy absorption, certain brittle fractures

occur during vapor polishing.

When a 3D-printed material undergoes vapor polishing, it can affect surface

roughness by reducing the roughness of the materials. There are always necessary details

to consider, including the mechanical qualities and finish improvements. One of them is

tensile testing, which is a process used to ascertain tensile strength. It tests if an

elastically manufactured 3D material can withstand tugging until it breaks into pieces.

The layer is inversely proportional to the strength of the specimen (Dwiyati et al., 2019).

13
As mentioned by Zharylkassyn et al., (2021), layer thickness, raster width, infill pattern,

and other characteristics are necessary for dimension accuracy which can have an impact

on overall preciseness. Depending on the kind of material, there are still some

temperatures related to dimensional variation. According to Marciniak et. al (2018), the

specimen's hardness and some mechanical properties decrease with prolonged contact

with acetone vapor because the acetone penetrates the 3D-printed materials differently.

The study added that the ABS thin layer would dissolve and have a smooth surface.

Acetone is the most commonly used chemical reagent in surface smoothing. It is a

non-hazardous and organic chemical (Pestano et al., 2022). As Xu et al. (2019) stated,

acetone is a colorless, flammable liquid with a boiling point of 56°C. According to

Coppola et al. (2022), acetone is known for its dominance of being low in toxicity and

having a fast diffusion. It is also famous for its low-cost advantages among various

chemical reagents. Moreover, Lalehour et al. (2018) state that acetone is an effective

solvent for post-processing techniques.

Related Studies

According to Mazzanti et al. (2019), Fused Deposition Modeling (FDM) 3D

printing has the distinct advantage of reducing costs while retaining the biodegradable

properties of the filament. However, FDM 3D-printed parts still need to undergo post-

processing as it is known for having poor layer adhesion strength and rough surface finish

(Tuazon et al., 2020). Surface finish is typically improved using the mechanical finishing

process. One of the popular surface treatments for ABS components is vapor polishing

which is the process of exposing 3D-printed parts to a solvent vapor to partially dissolve

14
the layer on the surface area. Vapor polishing also decreases surface roughness (Neff et

al., 2018).

Using a vapor polishing system as a tool for post-processing ABS parts for FDM

printers effectively reduces the surface roughness of 3D-printed parts. These studies serve

as a general point of reference for the experiments carried out in this study. It will also

serve as evidence of the significance of this investigation.

In addition, according to the study conducted by (Dizon et al. 2021), post-

processing is the process taken after being made from a 3D printer. Primary and

secondary are the two categories of post-processing. The primary process is necessary as

all 3D-printed parts must go through it before being used. While the secondary post-

processing was optional, aiming to improve the properties of the 3D-printed parts.

Primary post-processing is essential as it cleans the object. While secondary post-

processing was unnecessary, it depended on the users' demand.

Post-processing is significant for the improvement of mechanical and chemical

properties. This approach adds the most value and impact to a product. Creating aesthetic

effects is also one of its aims while increasing its mechanical properties.

This study shows the efficacy of post-processing procedures on the material used

for 3D printing and its effects on the mechanical/chemical properties that make the

product/material suitable for its application. It can also be used as reference material for

the effectivity.

In the study by Robles et al. (2022), which involved measuring the dimensional

accuracy of cube specimens, the size-related so-called "size effect," which is observed

while discussing its mechanical qualities, can be inferred to impact the samples' physical

15
dimensions. Since dimensionally accurate results are recognized as superior, the findings

of this study can be used as a basis to produce printed parts with the highest level of

dimensional accuracy.

In a study by Chohan et al. (2019), several experiments were carried out. The

experiments are made to determine the effect of polishing time and iteration on the

surface finish. The results of the experiments showed that as acetone vapor exposure

increased, the surface polish improved. Furthermore, adverse effects become apparent

once critical limits are exceeded, leading to deformation of the upper surface. For the

post-processing of ABS replicas, acetone was recommended.

The study above proves the vapor polishing system's effectiveness for post-

processing ABS 3D-printed parts. Additionally, it shows that acetone is an efficient

solvent for finishing ABS 3D-printed details. The current study should consider the vapor

polishing process's duration. The time the ABS 3D-printed parts spend in the acetone

solvent is critical to maintaining dimensional accuracy in 3D printing.

According to a recent study by Gache et al. (2022), they developed a vapor

polishing device to achieve standard polishing procedures used in laboratories. The study

shows that the process has dramatically reduced the roughness of the specimen, a

significant increase in the overall strength and ductility of the material, and that the vapor

polished cubes have an insignificant change in dimensions of about ±1 mm, which

concluded that the polishing procedure is effective enough to smoothen the surface of the

specimen while not altering the shape geometry of parts.

This research has important implications for this study in achieving a standard

polishing procedure in which dimensional accuracy, surface roughness, and tensile

16
strength were tested. In addition, this research shows that the device needs to be further

improved to achieve better results.

17
 DEFINITION OF TERMS

The following terms are defined conceptually and/or operationally.

Acetone. Non-hazardous and organic chemical, a colorless and flammable liquid with a

distinct smell and taste, evaporates easily.

Acrylonitrile Butadiene Styrene (ABS). A common type of thermoplastic polymer that

is typically applied in injection molding processes.

Additive Manufacturing. Also known as 3D printing is an approach to manufacturing

that involves combining materials to create items from a 3D model, often layer by layer.

Aluminum. A light, silvery-white metal, it is flexible and soft.

Digital thermostat temperature alarm. A digital device is used to regulate a

temperature of a material.

Fused Filament Fabrication (FFF).Also defined as FFF (fused filament fabrication). A

form of additive manufacturing (AM) where objects are built up layer by layer by putting

thermoplastic material through a heated nozzle.

Insulated Nichrome Coil. A thermodynamic device with a heating and cooling effect.

Post-Processing. Any procedure required to complete a printed item or any method

applied to improve the thing further.

Time relay module. Merely a time delay incorporated into relay control. They serve as a

time-based control for an event.

Vapor Polishing. Technique for polishing plastics that uses solvent vapor to gradually

melt a part's surface.

18
 CHAPTER III

CONCEPTUAL FRAMEWORK

This chapter presents the conceptual framework depicting a study's input, process,

and output involving dependent and independent variables. Engineering theory is also

applied in this chapter.

Conceptual Framework

INPUT PROCESS OUTPUT

 Existing design of  Modified device  The effectiveness of

vapor polishing  Printing of sample design optimization
device specimens
FEEDBACK of vapor polishing
device in terms of:
 Testing and
 A build plate cover →Dimensional
experimentation of
that is made out of Accuracy
sample
aluminum →Surface
→Dimensional
Roughness
 Insulated Nichrome Accuracy
Coil →Tensile Strength
→Surface →Impact
 Digital thermostat Roughness
temperature alarm  Effect of the study
→Tensile Testing on students,
 Time relay module →Impact test academic
institutions, and
 Time study of researchers
Acetone Evaporation
 Consumption Study

Figure 3.1. The paradigm of Study

The conceptual framework for this study uses the input-process-output (IPO)

framework, as shown in Figure 3.1. This conceptual framework presents the process and

19
preparation needed for this study, including the different methods used and the expected

outcome.

The first frame contains the study's primary input, which is the design

optimization of the vapor polishing device. This optimization was mainly implemented to

achieve the ideal function of the vapor polishing device and be more beneficial for the

DR3AM Center.

The second frame covers the different processes needed for the study. The process

will start with the modified device and printing of sample specimens. Afterward, testing

and experimentation of sample specimens with the vapor polishing device will be done to

identify its efficiency. These sample specimens will then be measured in terms of their

dimensional accuracy via a Mitutoyo Digimatic vernier caliper and surface roughness by

capturing the print's surface using a microscope that will be uploaded to Mountains9

Topography software. The specimen's tensile strength will be tested using Shimadzu

AGS-X Series Universal Testing Machine with 10kN capacity. Then, using pendulum-

dial Izod equipment from Cometech for impact test. The last process will be conducting a

time study of acetone evaporation and consumption study.

Lastly, the third frame contains the output of the study, which is the efficiency of

optimizing the vapor polishing device in terms of sample specimens' dimensional

accuracy, surface roughness, tensile strength, and impact resistance. And the significant

effect of the study on students, academic institutions, and researchers.

20
Figure 3.2 Flowchart of Investigation on the Effects of Acetone Vapor-Polishing to

Fracture Behavior of ABS Printed Materials at Different Operating Temperature

(Tuazon et. al, 2020)

21
Figure 3.3 Flowchart of Fabrication and Testing of a Vapor Polishing Device for ABS

3D-Printed Parts (Gache et. al,2022)

22
 Figure 3.4 Optimized Vapor Polishing DeviceProcess Flowchart

The experimentation of using acetone vapor polishing as post-processing for ABS

3D-printed parts has two past studies. Figure 3.2 was the process flowchart of the first

study by Tuazon et al. (2020). It is an experiment using an improvised acetone vapor

23
bath. Gache et al. (2022) studied fabricating a vapor polishing device using a mist maker;

Figure 3.3 shows its process flow chart. The last process shown above, Figure 3.4, was

the process flow chart for optimizing the vapor polishing device fabricated by the group

of Gache (2020).

Independent Variables

The independent variables of this study are mainly intended to enhance the

existing acetone vapor polishing device. The researchers control the development of the

optimized vapor polishing device; it includes the finding and assembly of materials to be

used to improve the said device. Additionally, the volume of the specimen, the average

temperature of the insulated nichrome coil to achieve the smooth acetone evaporation,

and the amount of time and acetone necessary to vapor polish the ABS 3D-printed parts

are other variables that the researcher will set during the testing and experimentation

phases.

Dependent Variables

In this study, the dependent variables include assessing the factors that affect the

efficiency and usefulness of the optimized vapor polishing device. These factors include

the result of the ABS 3D-printed part specimen’s dimensional accuracy, surface

roughness, tensile strength, and impact test. In addition, the effectuality evaluation of the

new base for the vapor polishing device and the insulated nichrome coil used for acetone

evaporation is also considered.

24
Engineering Theories Applied

Engineering theories are explored in this study, from planning and improving the

vapor polishing device to testing and experimenting with the sample specimens. These

engineering theories are:

The Enthalpy of Vaporization

The enthalpy of vaporization is the energy that a volume of liquid needs to

convert into a gas substance. In addition, the heat of a liquid's evaporation is related to the

thermodynamic temperature resulting from liquid boils (Moore et al., 2022). This theory

helps the researchers to determine the moderate heat required for the evaporation of

acetone in the vapor polishing process.

Thermal Conductivity

Thermal Conductivity is the ability of a material to conduct heat transfer. Meeting

the other design requirement of the device, considering the material's thermal

conductivity, is quite tricky since it may affect the device's performance. These past few

years, studies have been conducted on the book published by Wilkes et al. (2021)

contributes to the advances concerning thermal conductivity and enhancement of heat

transfer behavior in such materials. This theory helps the researchers to identify the

25
constraints they might encounter in applying heat transfer between the materials used to

improve the device’s structure.

Strength of Materials

Material strength is concerned with the material's ability to remain intact under

stress or carrying the load of a specific object. Actual operating conditions, fracture

resistance issues, failure theories, and stress-strain calculations for structural components

were also investigated (Chirkov, 2022). This theory was considered for selecting the

appropriate material for the base of the vapor polishing device.

Time and Motion Study

Time and motion study is an industrial engineering tool to determine the time

required for a particular occupation or activity. It can also help determine how

productively an employee works on a specific machine. Motions and time analysis could

help find a preferential way of doing the work and assist in effectively managing or

controlling the activity (Harper et al., 2018).

Material Planning

Materials Planning has been defined as the scientific way of determining the

requirements of raw materials, components, and other items needed for production within

economic investment policies. It is instead a sub-system in the overall planning activity.

26
(Aragwan et al. 2020). This theory helps the researchers to identify various materials to

be used for the device structure.

Material Control

The management function, known as material control, deals with the

procurement, holding, handling, and use of materials to reduce waste and losses, achieve

maximum economy, and establish accountability for various operations through physical

inspections, record-keeping, accounting, and other tools (Tamplin et al. 2022). The

researchers considered this theory on how to limit our waste and expenses throughout the

study.

Quality Control

Quality control, or QC for short, is a procedure by which organizations evaluate

the caliber of all production-related aspects. Engineers from the contractor perform it to

ensure the quality of the job while it is being produced (built). (Hashim et al. 2015). This

theory helps the researchers ensure the quality of the construction of the device as well as

the quality of each polished sample specimen.

Chemical Handling

The possibility of danger in any circumstance is known as Hazard. Hazardous

chemicals are elements that use in a variety of engineering industries. In the engineering

industry, an accident is any unanticipated occurrence that causes injury or damage.

Handling and environmental preventive methods for engineering chemicals are

mentioned for maintaining a safe working environment in the engineering industries

27
(Sivaprakash et al. 2014). This theory helps researchers to conduct proper chemical

handling (acetone) during laboratory experiments.

28
 CHAPTER IV

METHODOLOGY

This study presents the methodological framework for data collection and analysis

relevant to the research for the whole study, from design optimization to collecting data

and testing and evaluating the study results.

4.1 Methodology Framework

Figure

4.1.1

Process Flow Chart

29
4.2 Data Collection

According to Gache et al. (2022), it is evident that the DR3AM Center at BPSU

needs vapor polishing equipment for additional chemically secure polishing equipment

and a controlled polishing process. Thus, the general objective of this study is to improve

the performance of the existing vapor polishing device for ABS 3D-printed parts in the

DR3AM Center.

Additionally, different factors have been considered in optimizing the device,

such as chemical and material handling for the user’s safety and comfort. Also, the

previous study of the existing device has been taken into account for an efficient

improvement of the polishing device.

4.3 Design Preparation

Design optimization and other preparation needed for the optimization of the

existing localized vapor polishing device in the DR3AM Center at the Bataan Peninsula

State University (BPSU) are covered in this chapter including the Cost of Materials,

Fabrication of Parts, and Availability of Materials. Various criteria are considered by the

researchers in proposing a new method of optimizing the existing device vapor polishing

device.

4.4 Materials and Optimization

The optimization of the vapor polishing device was advanced using computer-

aided design software. The old base and cover of the device, which is PLA 3D-printed,

have remained. The following figures below show the considered optimized design of the

30
vapor polishing device. Figure 4.4.1 shows the CAD model of the previous vapor

polishing device using a mist maker; Figure 4.4.2 shows the CAD model of the optimized

vapor polishing device using a Peltier module. By the recommended and required design,

the vapor polishing device was advanced. Figure 4.4.3 is the CAD model of the final

design for the optimized vapor polishing device, and Figure 4.4.4 is the construction of

its final design.

Figure 4.4.1Figure 4.4.1CAD Model of the Previous Vapor Polishing Device Using Mist

Maker (Fabrication and Testing of a Vapor Polishing Device for ABS 3D-Printed Parts,

Gache et. al,2022)

31
 Figure 4.4.2 CAD Model of the Optimized Vapor Polishing Device Using Peltier

Module

Figure 4.4.3CAD Model of the Final Design for Optimized Vapor Polishing Device

32
 Figure 4.4.4 Optimized Vapor Polishing Device Final Design Construction

Vapor Polishing Procedure. For the first step, assemble the vapor polishing device and

check all components. Then, prepare the ABS 3D-printed part(s) and the acetone

(depending on the needed amount). Then, remove the glass chamber to put ABS 3D-

printed part(s) on the polishing table, and carefully place the glass chamber back. Using a

syringe, inject the designated amount of acetone through the tube (leads to the acetone

container) at the top of the device base. Plug the vapor polishing device into a power

outlet, select the desired temperature at the thermostat, and set the required time at the

time relay module. The insulated nichrome coil will heat up and produce acetone vapor.

The vapor produced will fill the entire glass dome and be absorbed by the ABS 3D-

printed part(s), resulting in a polished surface. Once the digital thermostat alarm obtains

33
the desired temperature, the insulated nichrome coil will automatically shut down and

stop producing heat. Then once the set time is done, unplug the device. Then, let it rest

for a few minutes to let the ABS 3D-printed part(s) absorb the remaining vapor. Then,

remove the glass dome carefully. Lastly, remove the polished ABS 3D-printed part(s),

and place it in a well-ventilated area to complete the curing of smoothened ABS 3D-

printed part(s). Finally, use a clean cloth to wipe and clean the glass dome. In addition,

keep the glass dome in a safe place to prevent it from breaking.

4.5 Testing and Evaluation

The material used in testing and experimentation in this study is Acrylonitrile

Butadiene Styrene (ABS) filament. ABS material is known for its flexibility, durability,

adaptability, and high heat tolerance; although it has interface lines within surfaces, it can

efficiently eliminate using acetone (Xometry, 2022). The commonly used post-processing

technique for ABS material is acetone smoothing, as the acetone can polish the lines

visible on the surfaces of the 3D-printed parts (Gregurić, 2023); with that, this study

utilizes Polymaker PolyLite ABS 3D Printer Filament for sample specimens. Compared

with standard ABS polymers, Polylite ABS has a much lower volatile component, which

provides outstanding printing quality and excellent post-processing capabilities

(Polymaker, 2023). The 3D-printed sample specimens in this study show slightly fine

lines of surface, indicating incomparable outputs from the previous study of Gache et al.

(2022), which have visible lines in 3D-printed sample specimens and used Z Ultrat ABS

3D printer filament.

34
 Dimensional Accuracy. The researchers will examine the dimensional accuracy

of polished and unpolished parts to evaluate the effectiveness of the optimized device.

Using Zortrax M200 3D printer, five (5) cube specimens were printed with 90% infill

density and 0.19 mm layer thickness with different dimensions starting from (10 mm)3,
3 3 3 3
(15 mm) , (20 mm) , (25 mm) , and up to (30 mm) using ABS filament. The dimensions of

five (5) specimens were measured and recorded using the Mitutoyo Digimatic Vernier

Caliper. Following the study of Robles et al. (2022), the researchers used three (3)

positions (top-to-bottom, front-to-back, and left-to-right) to get the dimension of

unpolished specimens. Accordingly, the cubes were polished to the optimized vapor

polishing device. Figure 4.5.1 shows the procedure for obtaining the dimensional

accuracy of the unpolished and polished cube specimens.

Figure 4.5.1 Cube Specimen Measurement

Surface Roughness.Mixing hot chemical vapors with heated air accelerates the

vapor polishing technique and produces an excellent surface finish (Singh, 2020). The

changes in surface roughness after the polishing process was measured using cube

35
specimens. The cube specimens were ABS 3D printed using the Zortrax M200 3D

printer. The sample specimens are 90% infill density, 0.19 mm layer thickness, and in

(10mm)³ size; The specimen's surface was captured and analyzed with an AMScope

MU503 T-720-Q and Mountains Topography software. The researchers measured the

3D-printed sample before being subjected to acetone in the optimized vapor polishing

device with a volume of 20 mL for 30 minutes and a curing time of 30 minutes. After

capturing and analyzing the polished cube specimen, comparing the findings acquired

from the unpolished was done.Figure 4.5.2 shows the actual capturing done in this study.

Figure 4.5.2

Tensile Test.The researchers conducted tensile testing of ABS 3D-printed parts in

accordance with ASTM D-638 Type IV, to determine the effect of the vapor polishing

device on the tensile strength of the 3D-printed parts (MTS, 2021). This study will use

the ASTM D-638 Type IV tensile specimen as the 3D-printed specimen. The specimen

has a thickness of 20 mm across the length, whereas the straight gage section has a range

of 750 mm and a width of 43 mm. The study used a total of ten (10) 3D-printed

36
specimens; five (5) are unpolished, while the other five (5) are polished. Each specimen

has a 90% infill density using the same printer for dimensional accuracy and surface

roughness specimens, the Zortrax M200. The researchers polished the tensile 3D-printed

specimen with the optimized vapor polishing device with 40 mL acetone. The process

will take an estimated 30 minutes and 30 minutes of curing time. This tensile test utilizes

a machine called Shimadzu AGS-X Series Universal Testing Machine with 10kN

capacity. Figure 4.5.3 below shows the tensile test setup and the specimen’s structure and

dimension.

Figure

Impact Test.The researchers used ASTM D256 test method E to obtain the

difference in impact resistance of unpolished and polished 3D-printed specimens, using a

pendulum-dial Izod machine. This ASTM standard test method is a single-point

assessment of the resistance of a material from breaking using a swinging pendulum

(Intertek, 2019). For preciseness, the equipment was thoroughly tested and calibrated in

line with ASTM D256 before the experiments. The Izod Type E Test Specimens were

37
printed in batches using the Zortrax M200 with a layer accuracy of 190 microns and an

infill density of 70%. Figure 8 depicts the actual impact testing.

Figure 4.5.4 Actual Impact Testing Arrangement

4.6 Time Study of Acetone Evaporation

A time study is used to determine the standard time for acetone evaporation.

Observing and recording the time taken in polishing each sample specimen is necessary

for calculating the time required for the vapor polishing of ABS 3D-printed parts.

4.7 Consumption Study

A consumption study is to determine the precise volume of acetone that should be

used in a specimen. This study will regulate how to minimize the usage of acetone and

maximize the resources. As the volume and other characteristics vary for each specimen,

38
acetone is also used in a certain quantity. This will give the 3D-printed parts the desired

appearance while using the proper amount of acetone for post-processing.

39
 CHAPTER V

RESULTS AND DISCUSSION

In this chapter, the result of the study is presented to determine the effectiveness

of the design optimization of the DR3AM vapor polishing device in the printed ABS

materials. The study aims to present and discuss the parameters of testing that were done

in the study; dimensional accuracy, surface roughness, and tensile strength.

Effectiveness of the Optimized Vapor Polishing Device

The study was able to vapor polish ABS 3D printed part(s) using the optimized

acetone vapor polishing device. But before achieving the ideal function of the optimized

device, the researchers undertake several testing and experiments to obtain the

appropriate module to use for the acetone vaporization. Considering the modules'

advantages and disadvantages, an Insulated Nichrome Coil indicates its edge over other

modules shown inTable 5.1

Table 5.1Advantages and Disadvantages of Different Modules

Modules Advantages Disadvantages

Initial Design Mist Maker Easy to use Perfect only for water-based but
inefficient use for chemical liquids.
Improved Peltier Small in size One side of the Peltier module gets
Design Module cold, which makes it incompatible
with the device since its cold side
might affect the electronic
components inside the base.

It is dependent on the Arduino

system to operate utterly.
Final Design Insulated Good conductor of
Its electrical wires are sensitive
Nichrome heat, perfect for
Coil acetone evaporation

40
 Acetone vapor polishing is a post-processing method for ABS 3D printed items

and is widely known for improving surface smoothness and reducing roughness.

Employing the insulated Nichrome Coil (heat method), it is possible to polish various

sizes of the 3D-printed specimen more quickly than with a mist maker; the Peltier module

has low efficiency for heating. Figure 5.1 shows the effectiveness of the optimized vapor

polishing device in post-processing different sizes. Since this post-processing uses a 99%

acetone that is enclosed, the device assures the safety of the chemical by leaking

throughout the experiment. Researchers recommended using a syringe to ensure the

specimen receives the exact amount of acetone. Compared to a mist maker, using an

Insulated Nichrome Coil consumes more acetone to complete, but the result is more

efficient and effective. In contrast to Gache et al. (2022), that used a mist maker in the

prior device had 1 hour polishing time and 30 minutes curing time, the optimized vapor

polishing device, which employed Insulated Nichrome Coil had 30 minutes polishing

time and 30 minutes curing time. As a result, the optimized vapor polishing device has

drastically reduced the polishing time while maintaining the same curing time.

(a) (b)
Figure 5.1 Images of (a) Unpolished Cube Specimens (b) Polished Cube

Specimens

Dimensional Accuracy.To evaluate the effectiveness of the vapor polishing

device, assessing the dimension accuracy of the 3D-printed specimen was examined. The

41
findings prove the unnoticeable alteration in the dimension, as it only shows an about ±1

mm difference from the unpolished and polished cube specimens. Equation 1 shows the

formula used for volume reduction in the dimension accuracy. By calculating the

percentage in volume reduction, the researchers determined the adequate volume of

acetone used in vapor polishing to smoothen the specimen while not changing its

dimension.

Volume Unpolished- Volume Polished

Volume Reduction (%) = ×100%
Volume Unpolished
(1)

Table 5.2Summary of dimensional changes for the Unpolished and Polished cube sample

Top to Bottom Front to Back Left to Right

Volume
Cube Size (mm) (mm) (mm) Reduction
3
(mm) Unpolished Polished Unpolished Polished Unpolished Polished (%)
10 10.25 10.20 10.13 10.10 10.12 10.07 1.29
15 15.15 15.15 15.05 15.03 15.07 15.05 0.26
20 20.21 20.18 20.07 20.05 20.15 20.08 0.60
25 25.15 25.02 25.12 25.06 25.14 25.07 1.03
30 30.10 30.10 30.20 30.16 30.10 30.05 0.30

Table 5.2 shows the summary of dimensional changes in unpolished and polished

specimens. Based on the findings, the data has no trend, as the different sizes of cube

specimens used various volumes of acetone, indicating no consistency in the result.

Surface Roughness. Figure 5.2 below shows the image of an unpolished 3D-

printed sample and a polished one after the vapor polishing procedure using the

optimized vapor polishing device. The researchers captured the digital images using the

42
AMScope software to evaluate the surface roughness of unpolished and polished

specimens. The findings show significant changes in the surface of the unpolished and

polished 3D-printed sample

Figure 5.2Digital Image of (a) Unpolished and (b) Polished Surface of 10x10 Cube

Specimen

Table 5.3shows the data gathered from the roughness analysis of unpolished and polished

specimens using the Mountains9 Software. It contains the Maximum Peak Height (Sp),

Maximum Pit Height (Sv), and Maximum Height (Sz). The roughness analysis shows a

difference of 2.416 µm and 2.68 µm for maximum peak height and maximum pit height

of unpolished and polished specimens. This data implies that the optimized vapor

polishing device reduces the surface peak and pit height of the 3D-printed sample

specimen and proves its effectiveness.

Table 5.3Results obtained by Mountains9 Topography Software

Sample Maximum Peak Height, Sp Maximum Pit Height, Maximum Height,

Sv Sp + Sv = Sz
Unpolished 3.668 µm 4.108 µm 7.775 µm
Polished 1.252 µm 1.428 µm 2.681 µm

43
 Tensile Strength. Table 5.4 shows the variations in tensile strength and Young's

Modulus for unpolished and polished specimens. The Young's modulus (E) of a material

determines how it responds to external stress in terms of reversible elastic deformation

and irreversible plastic deformation. Tensile strength was proportional to E for a given

material, but the relationship varied with material (Sun et al., 2018).

Table 5.4Tensile Strength and Young's Modulus of Unpolished and Polished Specimens

Tensile Tensile Average Tensile Young's Average

Test Samples Specimen Young's
Strength (MPa) Strength (MPa) Modulus
No. Modulus
1 44.520 2.462
2 45.219 2.521
Unpolished 3 45.722 46.354 2.201 2.369
4 48.153 2.236
5 48.155 2.426
1 36.908 3.047
2 37.307 2.856
Polished 3 41.616 40.713 2.886 2.877
4 43.138 2.718
5 44.596 2.877

After polishing the specimen, the researchers calculated the tensile strength and

elasticity of the polished and unpolished sample specimens. Figure 5.3 displays the

unpolished and polished test sample specimens after setting them through controlled

force until it breaks.

(a)
(b)

44
 Figure 5.3(a) Unpolished and (b) Polished Type IV Tensile Specimen

In addition, Figure 5.4 shows the summary of the curve for stress-strain and

Young's Modulus of unpolished and polished specimens using Origin software.

(a) (b)

Figure 5.4Summary of (a) Stress–Strain Curve and (b) Young’s Modulus of Unpolished

and Polished Type IV Test Specimens

Based on the tensile test results of both the unpolished and polished specimens,

the optimization of the vapor polishing device had a significant effect and impact on the

overall elasticity of the ABS 3D-printed specimens, yet the unpolished specimen yields

the maximum strength. Tensile property changes could be due to differences in size, but

they are more likely due to acetone vaporization on the polished ABS 3D-printed

specimens.

Impact Test. Using the Izod impact test, the researchers evaluated the breaking

strength of 3D-printed samples that were unpolished and polished in the optimized vapor

45
polishing device. Using formula 2, the researchers obtained the mean of the

experimentation, indicating the resistance of the specimen from a swinging pendulum.

Impact Resistance, I R = ES
(1)
w

Impact Energy, ES
(2) IE =
dw (2)

Table 5.5Summary of Mean Experimental Results of Impact Test

Post-processing Impact ResistanceJ/m Impact Energy J /m2

107.81 10611.47
77.61 7638.97
Unpolished 95.38 9388.25
123.44 12149.36
96.88 9534.94
107.58 10588.17
144.16 14188.76
Polished 118.44 11657.56
123.29 12134.61
112.46 11069.10

After absorption in acetone vapor, the researchers calculated the impact resistance

and energy of the polished and unpolished sample specimens. Table 5.5 presents the

result obtained after the Izod Impact test, which shows a cumulative increase of 17% in

impact resistance (IR) and impact energy (IE) of the sample specimen after acetone vapor

polishing.

46
 (a) (b)
Figure 5.5 Unpolished (a) and Polished (b) Izod Type E Specimen

(a) (b)

Figure 5.6 Summary of (a) Impact Resistance and (b) Impact Energy of Unpolished and

Polished Izod Type E Specimen

Figure 5.5 presents the unpolished and polished Izod Type E Specimen. While

figure 5.6 shows the summary of impact resistance and energy utilizing the scatter

diagram, comparing the result of polished and unpolished specimens. The figure presents

the increase of impact resistance (IR) and Impact Energy (IE) of polished 3D-printed

parts to unpolished ones.

Time Study of Acetone Evaporation

The vaporization time was tested out using a time study to determine the average

time needed for the vaporization of acetone. Five (5) trials were conducted for 20 mL, 30

mL, and 40 mL volumes of acetone with respective process vapor polishing. A time relay

module and the stopwatch were used as a tool to evaluate the time in each trial. After the

47
first polishing, the vapor polishing device was set to cool down before the second

polishing was done, and so on.

Table 5.6 Time Study for Acetone Evaporation

Acetone
Time (Seconds)
Volume
Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Average Time
20Ml 13.30 15.19 13.18 14. 41 15.32 14.280
30Ml 25.22 24.15 26.02 24. 10 25.28 24.954
40mL 30.12 30.20 29.11 31.01 30.29 30.146

The table 5.6 shows the average time in each amount of acetone has been

observed using a standard temperature of 37º Celsius in each experiment. This result will

serve as a guide for evaporating the amount of acetone in each experiment and specimen.

Consumption Study

The study will determine the acetone consumption of five (5) cube, Type IV

tensile specimen, and Izod Type E test specimen in correspondence with standard

temperature, testing, and experimentation of the sample specimens. According to the

study of Gache et al. (2022), an amount of 20 mL acetone was proved effective. Both

surface roughness and tensile strength of ABS material are effective in 20 mL volume

without affecting the dimensional accuracy of specimens. Thus, a 20 mL volume of

acetone, as well as 30 mL and 40 mL volumes for larger-size 3D-printed parts, were

considered in this study.

Table 5.7Consumption Study in Correspondence with Testing and Experimentation

10mm3 15mm3 20mm3 25mm3 30mm3 Type IV Impact

Acetone
Cube Cube Cube Cube Cube Tensile Test

48
 Volume Specimen Specimen
20Ml

30mL

40mL

The table 5.7 shows the appropriate amount of acetone each sample specimen

needed to be perfectly polished without affecting the dimensional accuracy. The check

(✔️) symbol represents the perfectly polished specimen, while the cross (✖️) symbol

represents the inefficient and overmuch amount of acetone for the size of the 3D-printed

parts. Based on the findings, the researchers concluded that a volume of 20mL acetone is

suitable for the (10 mm)3, (15 mm)3size cube specimens, 30mL for the , (20 mm)3size cube

andIzod Type E test specimen, and a 40mL volume of acetone for the sizes of (25 mm)3,
3
(30 mm) size cube and Type IV tensile specimen.

49
 CHAPTER VI

CONCLUSION AND RECOMMENDATION

This chapter summarizes and concludes the research work done, as well as the

recommendations, hypothesized driven by the findings.

Summary of findings

The optimized acetone vapor polishing device used the volume-based ratio of

Gache et al. (2022) to polish the different sizes of specimens. Different sizes of 3D-

printed specimens have different consumption of acetone, 20 mL for (10 mm)3 and
3 3
(15 mm) size of the cube, 30mL for(20 mm) andIzod Type E test specimen; 40mL for
3 3
(25 mm) , (30 mm) size of the cube, and Type IV tensile specimen. These are the

recommended volumes to be considered in ABS printed materials that have considerably

impacted the surface roughness and tensile strength without amending the dimension

accuracy of the specimens. various 3D-printed specimens will have different results

50
depending on the amount of acetone used, the time needed to polish each 3D-printed part,

and the brand of filament where in every brand has various chemical properties.Various

3D-printed specimens will have different results depending on the amount of acetone

used, the time needed to polish each 3D-printed part, and the brand of filament where in

every brand has various chemical properties. Specifically, the researchers observed the

following:

Dimensional Accuracy

The effect of vapor polishing on dimensional accuracy has been investigated. The

dimensional accuracy of the sample proves an unnoticeable alteration of about ±1 mm in

the dimensions of polished cubes. The findings indicate the effectiveness of the

optimized vapor polishing device in smoothing the surface of cubes without entirely

changing the physical geometry of the specimen.

Surface roughness

Acetone is used in the device in a volume-based ratio for vapor polishing ABS

3D-printed parts. The 3D-printed specimens were vapor polished using 20 ml of acetone,

which indicates a significant effect on the ABS material's surface roughness. According

to the roughness test, the polished specimen's maximum peak and pit heights have

significantly decreased. The specimen's roughness was greatly reduced as a result of the

data, which caused a sufficient change in the surface maximum height after using the

vapor polishing procedure.

Tensile strength

51
 The tensile test reveals that the overall elasticity of the 3D-printed Type IV tensile

specimen has increased significantly. This could be due to the softening of the 3D-printed

specimen's outer layer as acetone flows to connect in between layer gaps on the polished

3D-printed specimen's surface, resulting in greater elongation.

Impact Test

The impact test shows the specimen's capacity to sustain a resistive impact from a

swinging pendulum. It indicates that post-processing using the optimized vapor polishing

device significantly affects and increases 17% of the impact resistance of ABS 3D-

printed materials.

Recommendations

In light of the limitations and findings identified in the study, the researchers

concluded the following recommendation: a twice-a-year changeup of the acetone hose

for the yearly maintenance of the vapor polishing device; a replacement of the glass dome

as the existing one has an unequal rim and enormous size which affects the polishing

evaporation. Adding an exhaust fan on the base for electrical components is also vital for

the device. Utilization of an Arduino in a digital thermostat temperature alarm and time

relay module is necessary for cutting the power supplied to the nichrome coil after it

attains the set temperature and time. A rotating circular platform is also essential for

better polishing. The researchers also recommended fabricating and customizing a new

base and cover for the overall set-up of the device for a better appearance, as the existing

one isn't in good condition already. Upgrading the general system of the device is also

52
recommended for better function. In addition, the researchers recommended a separate

study on the curing time for further investigation; another is about the limitation of vapor

polishing to determine and ensure that the smoothing of the surface of a 3D-printed

specimen is already enough.

ACKNOWLEDGEMENT

The researchers would like to express heartfelt gratitude to all individuals and

facilities who have contributed to the successful completion of this group research study.

This study would not have been possible without the help, devotion, and knowledge of

the following:

Above all, to our Almighty God for His boundless love and for all the blessings

He has bestowed upon them. They are eternally grateful to God for guiding them during

their study. For the provisions and insight, He has granted them. For protecting them and

their loved ones. By His favor, they were able to finish without encountering any

difficulties.

To their beloved parents, who provided them with unending love, understanding

and encouragement, and more importantly, financial assistance throughout the duration of

the study.

53
 To Engr. Brian J. Tuazon, their capstone adviser, for his guidance, patience,

constant support by sharing his expertise and compassionately devoting his time

throughout the study.

To their capstone professor, Engr. Michaela T. Espino, and other faculty members

of Department of Industrial Engineering, Prof. John Ryan C. Dizon, Engr. Ramon

Francisco I. Jorge, Engr. Ruevan E. Alboro, Engr. Catherine R. Amboni, for helping,

teaching, and training them to be ready in facing the real world.

To DR3AM Center and its employees, for helping and allowing them to use the

facility and laboratory equipment throughout the study.

To the institution, Bataan Peninsula State University, which shaped them into the

person they become today.

They would also like to give special thanks to the previous researcher of the

study, Engr. Ciara Catherine L. Gache, for the support and inspiration. Also, to Mr.

Albert M. Bartolome, Mr. Jeyel V. Baluyot, and Mr. Felipe A. Sanchez, for helping them

with the technicalities of the study.

Thank you all once again for your invaluable assistance and guidance.

54
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 APPENDIX

CURRICULUM VITAE

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CURRICULUMVITAE

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