The Crucial Role of Metal Finishing in Additive Manufacturing (AM)

Metal finishing is needed in today’s incredibly fast-moving advanced world.

Additive manufacturing (AM) has transformed metal part production, enabling the creation of intricate geometries that traditional methods can’t achieve. However, 3D-printed metal parts often emerge with rough and uneven surfaces, both inside and out. To ensure these parts meet high standards of performance and aesthetics, metal finishing steps are essential.

Why Metal Finishing Matters

1. Smoothing Surface Roughness: AM processes like Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM) build parts layer by layer, which can leave surfaces gritty. Techniques such as polishing and abrasive flow machining (AFM) effectively smooth these surfaces, enhancing both appearance and functionality by reducing friction.

2. Refining Internal Features: Many AM parts feature complex internal channels and structures that are challenging to finish. Specialized methods like AFM can reach these hidden areas, ensuring internal surfaces are polished and optimized for better performance, such as improved fluid flow in medical or aerospace components.

3. Ensuring Dimensional Accuracy: The additive process may introduce slight distortions or size variances. Metal finishing processes help achieve precise dimensions, ensuring parts meet exact engineering specifications and fit seamlessly into their intended applications.

4. Enhancing Mechanical Properties: Surface imperfections can act as stress concentrators, potentially weakening a part. Finishing steps remove these micro-defects, boosting fatigue strength and overall durability, which is critical for high-performance industries like automotive and aerospace.

Unlocking Full Potential with Finishing Services

Integrating metal finishing into the additive manufacturing workflow transforms functional 3D-printed parts into high-quality products ready for market. This combination not only improves the visual appeal but also ensures parts are robust and reliable for real-world applications. For manufacturers, leveraging expert metal finishing services opens up endless possibilities for creating custom, beautiful, and highly functional metal components.

Embracing metal finishing is a vital step in maximizing the benefits of additive manufacturing, ensuring that every 3D-printed metal part meets the highest standards of quality and performance.

At Engineered Finishing Inc., we can guide you to finding the right process for your parts. Here’s a list of key metal finishing services that enhance additive manufacturing (AM) parts:

• Polishing

  • Smooths rough surfaces, improving appearance and reducing friction.

  • Provides a glossy or satin finish depending on specifications.

• Abrasive Flow Machining (AFM)

  • Ideal for internal channels and complex geometries.

  • Uses abrasive media to polish surfaces inaccessible by other means.

• Cryogenic Deburring

  • Freezes parts to remove small burrs or imperfections without damaging the part.

  • Maintains part integrity while refining edges and fine details.

• Electropolishing

  • An electrochemical process that removes surface layers, providing a mirror-like finish.

  • Reduces surface roughness and enhances corrosion resistance, commonly used for medical and food-grade parts.

• Vibratory Finishing

  • Uses vibrating media to smooth and polish parts, ideal for bulk processing.

  • Effective for cleaning and smoothing external surfaces.

• Bead Blasting

  • Blasts fine media (glass, ceramic, etc.) to clean, texture, or prepare surfaces.

  • Creates a uniform matte or satin finish on visible surfaces.

• Micro Machining

  • Fine-tunes intricate or small details on complex parts.

  • Helps with dimensional accuracy and surface refinement.

• Surface Grinding

  • Removes material from flat surfaces to achieve exact thickness and smoothness.

  • Suitable for parts with flat surfaces that need high precision.

• Shot Peening

  • Bombards the surface with small metal or ceramic shots to improve fatigue resistance.

  • Relieves surface stress, enhancing durability, especially in load-bearing parts.

• Chemical Etching

  • Uses chemical baths to clean or texture surfaces without physical abrasion.

  • Creates a uniform finish and can reduce surface roughness.

• Passivation

  • A chemical treatment to enhance corrosion resistance, especially for stainless steel parts.

  • Creates a clean, passive surface layer ideal for medical and aerospace applications.

Each of these services can be tailored to meet the specific requirements of AM parts, optimizing performance, aesthetics, and functionality.