Freeform structures constructed by AM technology have also stirred up the outlook on polishing tools designed to accommodate the unique surfaces of AM parts. Our team took a step further in adapting to the surface textures through retrofitted polishing tool designs and tool morphing functions [1]. We have developed several classifications of tool surface textures labelled as labyrinth, dimple, or hybrid variations that can be reversibly morphed by controlling air pressures filling the tool cavities. Each type of surface texture exhibits substantially different polishing pressure distributions and polishing accuracies to produce optical-grade finishing. As an extension for external finishing, we also have investigations on magnetic abrasive finishing [2], electrochemical polishing [3], conformal polishing [4], and micro-blasting [5].

Publications

[1] Q. Nie, et al., Development of morphable polishing tools with labyrinth and dimple textures, Journal of Materials Processing Technology, 303 (2022) 117539.

[2] J. Zhang, A. Chaudhari, H. Wang, Surface quality and material removal in magnetic abrasive finishing of selective laser melted 316L stainless steel, Journal of Manufacturing Processes, 45 (2019) 710–719.

[3] Y. Bai, et al., Dry mechanical-electrochemical polishing of selective laser melted 316L stainless steel, Materials & Design, 193 (2020) 108840.

[4] J. Zhang, et al., Vibration-assisted conformal polishing of additively manufactured structured surface, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 233 (2019) 4154–4164.

[5] J. Zhang, Micro-blasting of 316L tubular lattice manufactured by laser powder bed fusion, in: 19th International Conference & Exhibition of European Society for Precision Engineering and Nanotechnology (Euspen), Bilbao, Spain, 2019.

Acknowledgements

This research is proudly supported by the A*STAR Industry Alignment Fund (A19E1a0097).