Advanced Finishing Methods for Additively Manufactured Surfaces – A Comprehensive Review

Although Additive Manufacturing (AM) allows for the straightforward fabrication of geometrically complex components, post-processing is often necessary to enhance the surface finish and meet functional or aesthetic requirements. The surface finishing methods discussed in this review are classified into three broad categories such as mechanical (abrasive flow, vibratory), chemical/electrochemical (acid etching, electropolishing) and those that involve energy (laser polishing). Cross breeding methods of various techniques are also stated. Analysis is based on material compatibility, geometry complexity and economic instances that will help in selection of the process. A new trend is highlighted with regard to recent advances in automated as well as AI-driven finishing systems. The review offers effective information on how the given surface integrity of the AM parts could be enhanced especially in aerospace, medical, and automotive industry. The results concluded that post-processing is vital to acquiring practical surface properties in AM parts and determine the primary research directions in the future development of finishing technology.