Enhancing Surface Roughness of Polylactic Acid (PLA) 3D-Printed Parts Using CO₂ Laser Scanning: An Experimental Study on Parameter Optimization

Year : 2025 | Volume : 13 | Special Issue 06 | Page : 503 511
    By

    B Kiran Kumar,

  • K Tilak,

  • V Sai Deepak,

  • N Tarak,

  1. Associate Professor, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India
  2. Student, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India
  3. Student, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India
  4. Student, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Andhra Pradesh, India

Abstract

Fused deposition modeling (FDM) of polylactic acid (PLA) often suffers from poor surface finish due to the inherent layer-by-layer deposition process, limiting its use in high-precision applications. This study investigates CO₂ laser scanning as an efficient post-processing technique to reduce the surface roughness (Ra) of PLA parts while maintaining structural integrity. Specimens (100 × 80 × 5 mm) were fabricated with varying infill densities (35%, 70%, and 100%) to assess the influence of internal structure on laser treatment efficacy. The specimens were then processed using a CO₂ laser at different power levels (20–40%), scan speeds (200–350 mm/s), and scanning strategies (parallel, perpendicular, and diagonal). Results indicated that diagonal scanning induced void formation due to excessive localized melting, while perpendicular scanning led to layer delamination caused by uneven energy distribution. The optimal surface roughness reduction (up to 62% decrease in Ra) was achieved at 30% laser power and 300 mm/s scan speed, striking a balance between energy input and material removal. A mathematical model correlating laser energy density (LED) with Ra was developed, revealing a nonlinear relationship where excessive energy degraded surface quality. These findings provide actionable insights for industries requiring high-quality PLA surface finishes, offering a cost-effective post-processing solution that enhances FDM part functionality without compromising mechanical properties.

Keywords: Surface Roughness, CO2, Laser, PLA, FDM.

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
B Kiran Kumar, K Tilak, V Sai Deepak, N Tarak. Enhancing Surface Roughness of Polylactic Acid (PLA) 3D-Printed Parts Using CO₂ Laser Scanning: An Experimental Study on Parameter Optimization. Journal of Polymer & Composites. 2025; 13(06):503-511.
How to cite this URL:
B Kiran Kumar, K Tilak, V Sai Deepak, N Tarak. Enhancing Surface Roughness of Polylactic Acid (PLA) 3D-Printed Parts Using CO₂ Laser Scanning: An Experimental Study on Parameter Optimization. Journal of Polymer & Composites. 2025; 13(06):503-511. Available from: https://journals.stmjournals.com/jopc/article=2025/view=234111


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Special Issue Subscription Original Research
Volume 13
Special Issue 06
Received 30/05/2025
Accepted 26/07/2025
Published 16/09/2025
Publication Time 109 Days
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