Post processing of low cost Aligners fabricated by additive manufacturing process to enhance the surface quality and functionality.

Additive Manufacturing (AM) processes have ample advantages compared to traditional manufacturing processes, including mass customization, material efficiency, bioprinting, and fabrication of complex geometries with reduced lead time. Despite such benefits, it suffers most from staircase effects that deteriorate the fabricated part's surface quality. Nowadays, additively manufactured aligners are suitable for treating malocclusion and temporomandibular defects of teeth. Fused Deposition Modelling (FDM) is one of the best substitutes for clear aligners production to reduce per-unit cost. Glycol-modified Polyethylene Terephthalate (PETG) is opted as the material to fabricate the clear aligners due to its biocompatibility and non-toxicity. However, the poor surface quality of the additively manufactured is a major challenge in developing clear aligners with the FDM. A novel experimental setup is designed and developed to enable Chemical Vapor Smoothing (CVS) to enhance the surface quality of the clear aligners. Furthermore, based on the Surface roughness, the comparison is made between the surface quality polished with various chemicals (namely methylethylketone (also known as 2-butanone), toluene and, cyclohexanone). Moreover, Response Surface Methodology (RSM) is used to analyze the impact of different process parameters (i.e., the chemical volume, exposure time, and workpiece orientation) on the surface quality of the clear aligners. Moreover, RSM shows that the impact of the clear aligners orientation on %ΔR during the CVS is higher than other process parameters. Results demonstrate that cyclohexanone produces more uniform surface quality with a 92.73% reduction in surface roughness compared to methylethylketone and toluene on PETG, i.e., 89.66% and 88.63%, respectively. The developed surface finishing method is capable of producing uniform, smooth surfaces over the FDM-fabricated PETG clear aligners.