Impact of Post-Processing on Dimensional Accuracy of Parts

This article will discuss the different post-processing methods and their impact on dimensional accuracy, helping you navigate potential challenges and ensuring your designs achieve the precision and quality they require.
A person using a digital caliper to measure the thickness of a black 3D-printed part, with the caliper

In traditional manufacturing and additive manufacturing, the design and production phases are often the main focus. However, end products, whether they are industrial machines or electronic devices, often require post-processing to enhance their appearance or durability characteristics.

Post-processing in traditional manufacturing includes machining, polishing, and coating to smooth surfaces, remove excess material, or apply protective finishes. Additive manufacturing employs specific methods like support removal, surface smoothing, spray painting, and curing. For instance, resin 3D prints require UV light or heat post-curing to solidify and enhance their mechanical properties.

But what impact does post-processing have on the dimensional accuracy of parts? Will the part expand or contract? These are critical questions to consider when creating a 3D model to ensure that the part meets design specifications, functions correctly, and fits together seamlessly.

A person using a digital caliper to measure the thickness of a black 3D-printed part, with the caliper
Measuring the accuracy of a vapor-smoothed 3D-printed part using a digital caliper.

Common Post-Processing Techniques in Manufacturing

In designing, post-processing is important since it enhances part aesthetics as well as functionality. This also implies that it affects dimensional accuracy. There are several typical post-processing methods which are employed in CNC machining, sheet metal fabrication, and 3D printing:

  • Bead blasting: This technique uses a high-pressure stream of small beads, often made from glass or plastic, directed at the surface of the part, removing any faults it has and making it even all over. The process can smooth sharp edges slightly, thereby possibly changing key dimensions, particularly where intricate detail abounds.
  • Electropolishing: This is an electrochemical method that removes very thin layers from steel, ensuring shiny surfaces after cleaning. However, the removal process produces bluntness, and results in minimal adjustments to fit precision requirements due to dimension changes.
  • Vapor smoothing: Vapor smoothing involves bringing objects created from 3D printing in contact with chemical vapors, resulting in melting and regulating the outer surfaces. This process may alter small features and round off sharp edges, particularly for finely detailed parts.
  • Media tumbling: In addition to burr removal, media tumbling also polishes surfaces through placing them into vibratory containers fitted with abrasive media. This process is not suitable for fragile part features like sharp edges.
  • Sandblasting: Sandblasting uses high-speed particles for cleaning surfaces as well as texturing prior to painting or other treatments.
  • Powder coating: Here, dry powders are applied electrostatically onto an object that will then be heated to cure the coat into a long-lasting one. However, the process increases dimensions slightly and may cause trouble in fitting tight components together.
  • Plating: Plating involves depositing a metallic coating onto a surface to enhance electrical conductivity, wear resistance, and corrosion protection.
  • Anodizing: Anodizing, which comes in different types (Type II and Type III being the most commonly used), is an electrochemical process used for increasing the oxide layer on metal surfaces.
  • Passivation: This is the process by which stainless steel parts are treated to remove free iron and obtain better resistance to corrosion through the formation of a protective oxide layer.
  • Spray painting: This process is used to apply paint to parts for aesthetics and protection, potentially altering dimensions slightly.
Bead blasted

Bead blasting

Electropolishing

Media tumbling

Powder coating

Silver plating

Anodizing black

Anodizing (Type II)

Passivation

SLS PA12 3D printed part with a black spray painting finish

Spray painting

SLS PA media tumbled

Media tumbling

Vapor smoothing

Bead blasted
Anodizing black
SLS PA12 3D printed part with a black spray painting finish
SLS PA media tumbled

How Different Post-processing Techniques Impact Dimensional Accuracy

When considering post-processing for parts, it is important to understand how each technique impacts both dimensional accuracy and surface finish. The table below compares different post-processing methods (all available on Xometry’s Instant Quoting Engine®), including their effects on the material’s dimensional accuracy and the typical surface finish you can expect.

Technique Dimensional
Change
Surface
Finish
Typical
Applications
Materials They
Work With
Bead Blasting Negligible  Matte/satin,
grainy
Aesthetic finishing, surface
preparation for coatings
Metals, plastics,
composites
Electropolishing Slight reduction (0.00635 mm) Bright, smooth Improving corrosion resistance and smoothing out micro-peaks and valleys Stainless steel, aluminium, copper
Vapor Smoothing Minor reduction (~0.023 mm) Glossy, smooth Enhancing surface quality of 3D printed parts Thermoplastics
Media Tumbling Negligible Satin-like finish Parts with smoothed surface Metals, plastics
Sand Blasting Slight reduction (~0.005–0.025 mm) Dull finish Surface preparation for paint Metals, plastics
Powder Coating Addition (~0.02–0.05 mm) Matte or glossy, colored Wear-resistant parts, aesthetics Metals, plastics
Plating Addition (~0.005–0.025 mm) Metallic finish Electrical components, wear-resistant parts Metals (e.g., copper, nickel)
Passivation Negligible Matte, enhanced resistance Aesthetic enhancements, surface protection Stainless steel
Spray Painting Addition (~0.02–0.1 mm) Smooth, colored Surface enhancement and protection  Metals, plastics
Anodizing (Type II) Addition (~0.0025 mm) Matte or glossy, colored Corrosion resistance, durable parts Aluminium
Anodizing (Type III) Addition (~0.025 mm) Matte or slightly rough, colored High-wear applications, mechanical components, corrosion resistance,  durable parts Aluminium
Spray painting and vapor polishing Addition (~0.012–0.25 mm); slight reduction (negligible) Smooth, colored; Glossy, smooth Combining surface enhancement/protection and quality improvement for 3D printed parts Thermoplastic
Sand blasting and anodizing Negligible reduction (~0.0025–0.025 mm) Matte or satin, grainy; Matte or glossy, colored Surface preparation and protection for aluminium parts Aluminum

Regulations and Standards for Maintaining Dimensional Accuracy During Post-processing

Here is a brief overview of standards related to dimensional accuracy maintenance during post-processing commonly used in Europe, the UK and Turkey:

Standard Usage Objective Example of Application
ISO 2768 Establishes general tolerances for linear dimensions, angular dimensions, and geometrical tolerances in unassociated metal parts Ensures consistency in size throughout different manufacturing processes and post-production stages Indicating medium tolerances for a CNC-machined metal shaft with a 50 mm diameter as “ISO 2768-m” on the drawing
ISO 1101 Sets permissible limits for variations in part geometry, focusing on form and position tolerances Ensures components meet geometric standards despite dimensional changes during finishing operations Specifying perpendicularity: ⊥ 0.1 ISO 1101 for a hole to remain within a 0.1 mm tolerance zone relative to a given datum plane
ASME Y14.5 Describes how GD&T symbols specify allowable variations in sizes and shapes of parts using controls such as position control Ensures uniformity and high accuracy during and after manufacturing Using positional tolerance symbol on the drawing: Position: Ⓟ 0.2 | ⌀10 | A B C*
ASTM D618 Describes the practice for conditioning plastics for testing purposes after molding to test for thermal or chemical smoothing effects Ensures dimensional accuracy by conditioning samples for equilibrium before further operations Conditioning plastic samples for 48 hours at 50°C, then 96 hours at 23°C with 50% relative humidity before chemical smoothing

*The center of the hole must fall within a zone of 0.2mm diameter about datums ‘A,’ ‘B,’ and ‘C’ so that accurate assembly can be achieved during post-processing.

Tools and Technology for Monitoring and Controlling Dimensional Changes

Monitoring/controlling dimensional changes during post-processing requires accurate tools/technologies. Some key solutions include:

  • Coordinate Measuring Machines (CMMs): These machines use a probe to accurately measure the physical shapes of an object. They are useful for checking measurements as well as detecting any deviation from design specifications. They excel in precision, often achieving measurements within micrometers (0.001 mm), far surpassing the typical accuracy of digital calipers, which is around 0.01 mm.
  • Laser scanners: Laser scanners provide non-contact measurement. They generate high-resolution 3D models of parts that are then compared to CAD designs to ascertain any dimensional change.
  • Optical comparators: These devices project the profile of a part onto a screen and allow for visual comparison against pre-set standards. They are most useful in monitoring dimensional changes in small and intricate parts.
  • Digital calipers and micrometers: For fast, accurate measurements, digital calipers and micrometers provide excellent accuracy when it comes to measuring lengths or thicknesses, which is imperative for quality control.
  • Surface roughness testers: These determine surface finish quality by identifying changes that would affect dimensional accuracy resulting from practices like sanding or polishing through post-processing.
Engineer using a coordinate measuring machine (CMM) to inspect a 3D-printed part in a lab setting
Engineer inspecting a part using a coordinate measuring machine (CMM) for dimensional accuracy

How to Reflect Tolerances on Technical Drawings

  • To reflect the finishing processes, such as anodizing, on technical drawings, it is necessary to indicate post-treatment tolerances for any specific customer requirement (e.g. hard anodizing 50µm). 
  • Clearly specify on the drawing that tolerances on the drawing are post-treatment.
  • For thin treatments (<10 µm), final tolerances can often be assured. For any treatments thicker than 10 µm, it is recommended to mask certain surfaces to prevent unpredictable dimensional changes post-treatment (e.g. mask threaded holes to ensure they remain within tolerance and functional after a thick anodizing layer is applied).
  • Add any surface finish symbols (roughness) and specific tolerances (linear or geometric) that will ensure the part meets its functional requirements.
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