One of the many things that fused deposition modeling (FDM) 3D printers lack is the smooth finish you get from injection-molded parts. The surface of FDM parts has a rather matte, rough finish with visible layer lines, regardless of the layer height employed during printing.
Post-processing will be required to eliminate these layer lines, and one of the most popular ways is sanding and filling until a smooth surface is achieved. As you can imagine, this can takes ages to get anywhere close to smooth.
However, a reasonably popular workaround solution for post-processing 3D printed parts is acetone vapor smoothing. This method can be applied to any material that can be dissolved in acetone but is mostly used with ABS filament.
Acetone is a colorless solvent that’s mainly used for cleaning purposes. ABS is highly reactive to acetone, and it’s possible to dissolve only the topmost surface of ABS parts by using acetone in vapor form. This completely eliminates any visible layer lines and gives you a clean and smooth surface finish.
There are some drawbacks to this method, though. It can be hard to control the smoothing process, so some dimensional accuracy and small details can be lost after it’s done. Moreover, pure acetone is considered a safety hazard and must be handled with the utmost care, as we’ll see next.
Acetone can be an adequate (although uncommon) tool for everything from cleaning your hot end to welding together 3D printed parts. However, you need to keep in mind that acetone is a hazardous chemical in its purest form.
To begin with, acetone is a highly flammable and volatile substance that can ignite at room temperature, so never use it near fire or anything that can create a spark. Also, ensure that acetone is stored in cool, well-ventilated areas away from direct sunlight and heat sources.
In terms of potential health effects, high purity acetone can cause headaches, nausea, dizziness, drowsiness, and confusion if inhaled, according to the Canadian Centre for Occupational Health and Safety. Be sure to always work in a well-ventilated area and use respiratory protection equipment such as gas masks whenever possible.
Other personal protective equipment such as non-nitrile gloves as well as eye and face protection is also highly advised because skin and eye exposure can cause mild to severe irritation.
Due to all these potential safety hazards, pure acetone can be a little troubling to source in some countries. Check out the current regulations in your country before considering this smoothing method.
There are countless methods for acetone smoothing your 3D print, some more dangerous than others. If you’re still committed to acetone smoothing, there’s a simple way to do it with everyday household items. Besides the protective equipment mentioned before, here’s what you’ll need:
Before handling the acetone, let’s set up the container and parts.
Now, we’re ready to handle the acetone and get this smoothing started.
Now, we just have to wait until the liquid acetone vaporizes and starts dissolving the layer lines of the 3D printed part.
The duration of the process widely varies depending on the size of the part, the size of the container, the room temperature, and even how tightly the container is sealed. Usually, it can take anywhere from half an hour to a couple of hours. For reference, the Budda Yoda shown took just under two hours.
It should be much easier to follow the progress of the smoothing process with a transparent glass container. Otherwise, we would have to guess or even open the container, which would allow the vapor to escape.
There’s always a chance of over-smoothing the part, leading to the loss of all surface details or, worse, completely distorting the part. This is why a transparent container comes in handy.
It can take some practice to perfect the time required to get your desired level of surface finish, so don’t worry. After a little hands-on experience, you’ll figure out the best settings for yourself.
Once you’re satisfied with how your part looks, it’s time to stop the process and let the dissolved surface dry out to become rigid again.
Be patient and enjoy. After all, this is when you’ll actually see the magic of acetone vapor smoothing. The part will start to look more shiny and polished when drying, and soon enough, you’ll be able to show off your injection-mold-looking part.
There you have it: a finished acetone-smoothed part that barely looks like it was 3D printed. Have a go at it, and you’ll be amazed by the results you achieve once you perfect the method.
Trust us! You’ll only want to try it more and more.
License: The text of "ABS Acetone Smoothing: 3D Print Vapor Smoothing Guide" by All3DP is licensed under a Creative Commons Attribution 4.0 International License.