Enhancement of mechanical and surface properties by ball burnishing process on polymeric components obtained by FFF

Purpose: This paper aims to investigate and deliver experimental evidence to establish ball burnishing (BB) as an effective procedure for processing fused filament fabricated parts (FFF). This study, which is a novel contribution to applying BB on FFF parts of materials with different properties, demonstrates the validity of this technology on polymers and provides generalizations for its implementation. Design/methodology/approach: A BB tool has been designed and validated. Statistical models have been used to determine the process parameters that provide the best results. In addition, the process’ impacts on the dimensional accuracy, quality, hardness and mechanical performance of the treated parts under static bending and fatigue testing have been quantified and compared to the untreated samples. Findings: This study shows the best combination of process parameters for two printing orientations which have been decisive in obtaining successful results. These positive results allow stating procedure guidelines and recommendations for use in the industrial environment. Originality/value: This paper fulfills an identified need to enhance FFF parts' surface and mechanical properties, as more experimental evidence of studies demonstrating this technology's validity in additive manufacturing is yet to be found.