Exploring the Impact of Surface Modifications on the Mechanical Characteristics of Acrylonitrile Butadiene Styrene Parts Manufactured Using Fused Deposition Modeling 3D Printing

The metallization of 3D printed plastic structures has sparked widespread interest and intrigue among researchers and industry professionals alike. However, the compatibility issue arises between metal and plastic additive manufacturing technologies due to their substantial discrepancy in process temperatures. This paper explores refining fused deposition modeling by investigating the impact of copper electroless plating on 3D printed acrylonitrile butadiene styrene (ABS) parts. Electroless plating, a form of chemical metal deposition unlike conventional methods deposits metal without an electrical current. The 3D printed structure undergoes direct immersion in a copper (Cu) electroless plating bath, ensuring strong uniform adhesion. The research addresses challenges associated with ABS porosity and roughness, with a particular emphasis on surface preparation, adhesion, and dimensional stability. The proposed plastic 3D printing technology, combined with electroless plating, eliminates the need for etching or roughening of the ABS structure. Assessment criteria include ASTM standard surface finish and mechanical behavior (tensile, flexural, and hardness). Scanning electron microscopy reveals uniform copper plating, and results indicate superior mechanical properties and surface roughness in copper plated ABS specimens compared to non-plated ones. The research article highlights a remarkable improvement in mechanical properties post-electroless plating, with increases in tensile strength by approximately 81%, compression strength by 37%, Shore D hardness by 39%, and impact resistance by 81%, alongside a notable reduction in surface roughness by approximately 92.5%, affirming the efficacy of the plating process in enhancing material performance and surface quality. The findings offer crucial insights for ASTM-compliant FDM 3D printing advancements.