Post-Treatment Methods in Additive Manufacturing: A Review of Mechanical, Thermal, Chemical, and Hybrid Approaches

Year : 2025 | Volume : 16 | Issue : 03 | Page : 25 34
    By

    Yogesh Matre,

  • Monil Jain,

  • Shaheen Beg Mughal,

  • Dharmesh Barodiya,

  • Chinmay Saraf,

  1. Research Scholar, Department of Mechanical Engineering, Prestige Institute of Engineering Management & Research, Madhya Pradesh, India
  2. Assistant Professor, Department of Mechanical Engineering, Prestige Institute of Engineering Management & Research, Madhya Pradesh, India
  3. Assistant Professor, Department of Mechanical Engineering, Prestige Institute of Engineering Management & Research, Madhya Pradesh, India
  4. Assistant Professor, Department of Mechanical Engineering, Prestige Institute of Engineering Management & Research, Madhya Pradesh, India
  5. Assistant Professor, Department of Mechanical Engineering, Prestige Institute of Engineering Management & Research, Madhya Pradesh, India

Abstract

Additive manufacturing, particularly Fused Deposition Modeling (FDM), has become a cornerstone of rapid prototyping and functional part production due to its accessibility and material versatility. However, the inherent layer-by-layer nature of FDM introduces surface roughness, reduced mechanical strength, and anisotropic behavior, which limit its industrial applications. This literature review investigates the impact of chemical post-processing treatments such as solvent vapor smoothing, immersion, and hybrid chemical-thermal methods on the surface quality and mechanical performance of FDM-printed components made from commonly used thermoplastics like PLA, ABS, and PETG. A comprehensive analysis of recent experimental studies reveals significant improvements in surface finish, tensile strength, and fracture resistance following controlled chemical treatment. The review also highlights the material-specific behavior, solvent compatibility, safety considerations, and potential drawbacks such as dimensional distortion and reduced ductility. The insights gained serve as a foundation for optimizing post-processing protocols, enabling the broader use of FDM parts in end-use, load bearing, and visually demanding applications. Mechanical methods such as machining, abrasive finishing, and shot peening improve dimensional accuracy and surface finish; thermal treatments like annealing, laser remelting, and hot isostatic pressing (HIP) relieve internal stresses and reduce defects; and chemical processes, including electrochemical polishing and solvent vapor smoothing, provide superior surface uniformity. Hybrid post-treatment techniques that combine multiple methods are gaining prominence for achieving optimized performance and efficiency. The paper also discusses current challenges, recent advancements, and future research directions aimed at integrating automated and energy-efficient post-processing within the AM workflow. Overall, this review underscores the critical role of post-treatment in bridging the gap between as-built and application-ready AM parts, enabling their broader adoption in high-performance industrial sectors.

Keywords: Fused deposition modeling (FDM), chemical post processing, solvent vapor smoothing, surface roughness, mechanical properties, dimensional accuracy, PLA, ABS, PETG

[This article belongs to Journal of Experimental & Applied Mechanics ]

How to cite this article:
Yogesh Matre, Monil Jain, Shaheen Beg Mughal, Dharmesh Barodiya, Chinmay Saraf. Post-Treatment Methods in Additive Manufacturing: A Review of Mechanical, Thermal, Chemical, and Hybrid Approaches. Journal of Experimental & Applied Mechanics. 2025; 16(03):25-34.
How to cite this URL:
Yogesh Matre, Monil Jain, Shaheen Beg Mughal, Dharmesh Barodiya, Chinmay Saraf. Post-Treatment Methods in Additive Manufacturing: A Review of Mechanical, Thermal, Chemical, and Hybrid Approaches. Journal of Experimental & Applied Mechanics. 2025; 16(03):25-34. Available from: https://journals.stmjournals.com/joeam/article=2025/view=233270


References

Regular Issue Subscription Original Research
Volume 16
Issue 03
Received 29/07/2025
Accepted 14/09/2025
Published 16/10/2025
Publication Time 79 Days
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