Identifying Critical Post-Processing Criteria for Enhancing Surface Finish of FDM-Printed ABS Automotive Exterior Parts

Mohd Haidiezul Jamal Ab Hadi; Mohd Shahrizal Dolah; Saiful Hasley Ramli; Khairul Manami Kamarudin; Muhammad Aiman Ahmad Fozi; Noorhafiza Muhammad; Mohamad Syafiq Abdul Khadir

doi:10.58915/aset.v5i1.3198

Authors

Mohd Haidiezul Jamal Ab Hadi Universiti Malaysia Perlis
Mohd Shahrizal Dolah Universiti Putra Malaysia
Saiful Hasley Ramli Universiti Putra Malaysia
Khairul Manami Kamarudin Universiti Putra Malaysia
Muhammad Aiman Ahmad Fozi Universiti Malaysia Perlis
Noorhafiza Muhammad Universiti Malaysia Perlis
Mohamad Syafiq Abdul Khadir Universiti Malaysia Perlis

DOI:

https://doi.org/10.58915/aset.v5i1.3198

Keywords:

Additive manufacturing, Automotive exterior parts, Fused Deposition Modeling (FDM), Surface finishing, Surface quality

Abstract

The increasing adoption of Fused Deposition Modeling (FDM) in automotive manufacturing is constrained by poor surface quality, primarily due to inherent layer-based defects and process-parameter variability. This study aims to identify the critical post-processing criteria that influence the surface finish of FDM-printed ABS automotive exterior parts. A qualitative research approach was employed, involving semi-structured interviews with domain experts, followed by systematic analysis in ATLAS.ti. The data were evaluated through groundedness (Gr) and network density (Gs) to capture both frequency-based importance and structural relationships among factors. A total of 36 codes were generated and subsequently synthesized into six key themes: surface finish duration, factors influencing quality, surface finishing process, mechanical finishing, chemical finishing, and surface quality. The findings indicate that surface finishing is a highly interdependent system, with chemical finishing techniques and process control parameters emerging as dominant contributors to improved surface quality. Surface quality was identified as the central outcome, influenced by both upstream fabrication and downstream finishing processes. This study provides a structured understanding of the critical factors governing finishing effectiveness, offering preliminary insights to support consistent improvement of visual and functional quality in automotive applications, while contributing to sustainable manufacturing practices (SDG 9 and SDG 12).

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