iCAT 2026 PLENARY SPEAKERS

We have also invited certain notable guests to share their expertise in the field of 3D printing and its future applications.

Joško Valentinčič

Faculty of Mechanical Engineering, University of Ljubljana, Slovenia

Post-Processing of Additively Manufactured Metal Parts: An Overview with Focus on Plasma Electrolytic Polishing

Additive manufacturing enables the production of highly complex metal components with unprecedented design freedom, yet the surface condition of as-built parts often remains a major limitation for demanding engineering applications. Typical surface-related issues include high roughness, partially melted or adhered powder particles, staircase effects, oxidation, cracks, porosity and other near-surface defects, all of which may impair aesthetics, dimensional accuracy, corrosion resistance and especially fatigue performance. For this reason, surface post-processing is an essential step in the AM process chain rather than a secondary finishing operation. A wide range of technologies is currently used, including machining, sandblasting, tumbling, abrasive flow machining, shot peening, ultrasonic impact treatment, laser polishing, chemical polishing, electropolishing, dry electrochemical polishing and plasma electrolytic polishing, often in combination to achieve the required surface integrity and functional performance.

The presentation provides an overview of the main surface post-processing technologies for metal AM parts and then focuses on plasma electrolytic polishing (PeP) as a particularly promising approach for complex geometries. After introducing the basic principles of PeP, the presentation discusses its application to the surface post-processing of additively manufactured components and highlights its potential for improving surface quality and functional behaviour. Particular attention is given to the remaining challenges associated with internal features, including lattice structures, where restricted accessibility, non-uniform material removal and process stability make it difficult to achieve consistent roughness reduction and enhanced mechanical properties.

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