best post processing method to get smooth prints

Hi,

I got a request to print a cosplay helmet for someone, but I dont want to sand PLA, or bondo such complex structures.

Im familar with the polysmooth system and im thinking about building a bigger polysher --> [filament2print.com]

but i wonder if there isnt a generally accepted better way or maybe a new material that i havent heard of that sands better than PLA?

Cheer F

... printingwith ABS and then vapoursmoothing with Acetone maybe?

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Viktor
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Call for the project "garbage-free seas" - [reprap.org]

yeah, this is a possibility but i havent found a clear recipe that avoids the parts getting weak, (a possibility that exists with the polysher as well).
and acetone vapors are probbaly unhealthier than alcohol vapors.

but i imgine that my proposed bigger polysher could handle acetone as well.

Sand blasting ?
The downside is the need for the equipment, and most of all a powerfull compressor. 5+ HP or it will take ages.
Seems to me PCBWay, JLCPCB and other do it this way.

Could a tumbler do it ?

For PLA, chlorinated solvents work the same way acetone works for ABS. But not easy to source.

Likely out of your price range, but the E3D tool changer has an option called ASMBL which uses a small milling tool to do the finishing of the print.

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Large delta printer [miscsolutions.wordpress.com], E3D tool changer, Robotdigg SCARA printer, Crane Quad and Ormerod

Disclosure: I design Duet electronics and work on RepRapFirmware, [duet3d.com].

@dc42

yeah looking forward to what the new prusa will be able to do on that front.
or putting a little spayer on one of the toolheads and spraying solvent around the model every few layers could also be interesting.



looking at my research over the last 2 days XTC3D paint on resin or alcohol vapor smoothing are my favorites so far.

Quote
sungod3k
Hi,

I got a request to print a cosplay helmet for someone, but I dont want to sand PLA, or bondo such complex structures.

Im familar with the polysmooth system and im thinking about building a bigger polysher --> [filament2print.com]

but i wonder if there isnt a generally accepted better way or maybe a new material that i havent heard of that sands better than PLA?

Cheer F

I recently did a full sized helmet for a friend.
Printed PLA then used a bondo type with the flexible spreader so it was applied smoothly to the curves of the helmet.
After carefully sanding then used automotive primer and paint for a mirror finish.
Mine was all done by hand.

It does take care, and precision but not all that difficult to get a great result.
The use of automotive primer in multiple colors allows one to fill in minor imperfections for a great result. Just like in a body shop paint booth.