Before
After
Objective
Develop a repeatable post-processing workflow to remove DMLS build lines and machining marks from a 3D-printed titanium ankle/partial knee component, then polish to a smooth, low-roughness, implant-grade surface finish suitable for medical use.
| Part Description | Ankle and Partial Knee |
| Industry | Medical/Pharmaceutical, 3D Print Post-Processing – Metal |
| 3D Printing Technology | DMLS/SLM |
| Material | Titanium |
| Process Type | Deburr, Polish, Ultrapolish |
| Equipment Type | High Energy, Multiple Technologies |
Solution
Bel Air developed a high-energy finishing approach to remove DMLS surface roughness and achieve a smooth, low-Ra surface on the titanium implant geometry. Care was taken to preserve the part’s contoured form smoothing surface texture and blending layer-step artifacts.
Depending on production volume and finish requirements, Bel Air recommended either of two high-energy mass finishing methods capable of delivering controlled material refinement:
- High-Energy Disc Finishing for efficient batch processing and faster roughness reduction
- High-Energy Barrel Finishing/Haperizing for precision polishing on curved implant surfaces where dimensional control is critical
This approach enabled the implant to reach a uniform, polished surface suitable for medical handling and final inspection, while reducing or eliminating manual polishing steps and improving process repeatability.
If you are unsure what equipment and media you require to achieve your desired surface finish, then send us your part, and we will evaluate it and provide you with a metrology report.
To explore various achievable finishes, you can also request a comparative keychain sample showcasing a range of surface textures and polish levels.