The Influence of Model Orientation on the Surface Roughness of Polymeric Models Produced by FFF, mSLA, PJ, and SLS Methods

The research methodology involved creating a 3D sample model that featured both flat and cylindrical surfaces inclined at angles ranging from 0° to 90° relative to the XY plane. The study investigated the surface topography of additively manufactured samples produced using various technologies, including Fused Filament Fabrication (FFF), masked Stereolithography (mSLA), PolyJet (PJ), and Selective Laser Sintering (SLS). The focus was on how material type, print angle, and measurement location influenced the results. The materials used in the study included PLA, PETG, acrylic resins, PA2200, and VeroClear. Due to the optical properties of the materials used, measurements were carried out on replicas that were prepared using a RepliSet F5 silicone compound from Struers. Consequently, a methodology was developed for measuring surface roughness using the Alicona microscope based on these replicas. A 10× objective lens was used during the measurements, and the pixel size was 0.88 µm × 0.88 µm. Each time, an area of approximately 1 mm × 4 mm was measured. The lowest roughness values were observed for mSLA samples (Sa = 6.72–8.54 µm, Spk + Sk + Svk = 33.36–42.16 µm), whereas SLS exhibited the highest roughness (Sa = 27.86 µm, Spk + Sk + Svk = 183.79 µm). PJ samples exhibited intermediate roughness with significant anisotropy (Sa = 11.65 µm, Spk + Sk + Svk = 72.1 µm), which was strongly influenced by the print angle. FFF surfaces showed directional patterns and layer-dependent roughness, with the Sa parameter being the same (12.44 µm) for both PETG and PLA materials. The steepest slopes were observed for SLS surfaces (Sdq = 7.67), while mSLA exhibited the flattest microstructure (Sdq = 0.48–0.89). Statistical analysis confirmed that material type significantly influenced topography in mSLA, while print angle strongly affected PJ and FFF (although for FFF, further studies would be beneficial). The results of the research conducted can be used to develop a methodology for optimizing the printing process to achieve the required geometric surface structure.