Gabriele Scordamaglia

The Fused Deposition Modeling (FDM) process often produces parts with high surface roughness, limiting their end-use applications, especially in the biomedical field. This paper presents an experimental study on improving the surface finish of 3D-printed polycaprolactone (PCL) samples using a robotic burnishing process. A key innovation is the development of a low-cost sensorless setup using a 5-DOF manipulator, which controls the applied force by correlating a precise robotic displacement with the known stiffness of springs via Hooke’s law. Ten PCL samples were tested using two burnishing directions: 90° (perpendicular) and 0° (parallel) relative to the printing orientation. The as-printed samples showed a highly anisotropic surface. The 90° trajectory (group 1) proved to be more effective in reducing primary roughness ($R_{a_{\perp }}$), lowering the mean $R_a$ from $2.11\mathsf{\mu }\mathrm{m}$ to $1.44\mathsf{\mu }\mathrm{m}$ (a mean reduction of 29.9%). In contrast, the 0° trajectory (group 2) was more effective in reducing roughness $R_{a_{\Vert }}$, lowering its mean $R_a$ from $0.225\mathsf{\mu }\mathrm{m}$ to $0.144\mathsf{\mu }\mathrm{m}$ (a mean reduction of 34.0%). The results demonstrate that the proposed sensorless system is a valid method for surface post-processing of FDM parts when the required forces fall below a specific threshold, ensuring a significant reduction in roughness without damaging the samples. The lower surface roughness obtained with the proposed post-processing strategy may represent a promising approach for improving the surface characteristics of FDM-fabricated polymer scaffolds intended for biomedical applications.