How do you overcome the low resolution and surface roughness of laminated object manufacturing?

1 Choose the right material

The material you use for LOM affects the resolution, surface finish, and strength of your prototype. Paper is the most common and cheapest material, but it has low resolution and roughness, and it can warp or burn easily. Plastic is more durable and flexible, but it has higher shrinkage and lower adhesion. Metal is the strongest and most accurate material, but it is also the most expensive and difficult to process. Depending on your project requirements, you should choose the material that best suits your needs and budget.

2 Adjust the laser parameters

The laser that cuts the layers of material in LOM also affects the resolution and surface finish of your prototype. The laser power, speed, and focal point determine the size and shape of the cut, as well as the amount of heat and smoke generated. If the laser power is too high, it can cause charring, melting, or cracking of the material. If the laser speed is too low, it can cause excessive heat and smoke that can damage the material and the machine. If the laser focal point is not aligned, it can cause uneven or inaccurate cuts. You should adjust the laser parameters according to the material type, thickness, and desired resolution.

3 Apply post-processing techniques

Post-processing is an essential step to improve the quality and appearance of your LOM prototype. There are several techniques you can use to smooth, polish, or coat the surface of your prototype, such as sanding, filing, grinding, painting, or varnishing. You can also use post-processing to remove excess material, glue, or smoke residues, or to join or reinforce parts of your prototype. Post-processing can enhance the aesthetic and functional aspects of your LOM prototype, but it can also add time and cost to your project.

4 Use software tools

Software tools can help you optimize your LOM design and process, as well as evaluate and correct errors or defects. You can use software tools to create or modify your 3D model, to slice it into layers, to generate the laser path, and to control the machine parameters. You can also use software tools to simulate the LOM process, to analyze the stress, strain, or deformation of your prototype, and to detect and fix gaps, overlaps, or misalignments. Software tools can save you time and resources, and improve the accuracy and quality of your LOM prototype.

5 Experiment and test

The best way to overcome the challenges of LOM is to experiment and test your prototype. You should try different materials, laser settings, post-processing methods, and software tools, and compare the results. You should also test your prototype for its performance, functionality, durability, and usability. You should measure and evaluate the resolution, surface finish, and mechanical properties of your prototype, and identify the strengths and weaknesses. You should also solicit feedback from your clients, users, or stakeholders, and incorporate their suggestions or preferences. Experimenting and testing can help you learn from your mistakes, improve your skills, and achieve your goals.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?