The surface structure in the form of waviness and roughness as well as near surface density of FFF parts
represents a major issue with respect to mechanical performance especially under fatigue loading. Mechanical
surface treatments like shot peening or rolling are commonly used techniques, especially for metal components,
to reduce surface roughness, increase surface densification and create beneficial residual stress states in the
surface layer. In this study, a rolling process has been applied intermittently with the layer-wise FFF process and
the effect on the surface state has been investigated using laser scanning and optical microscopy as well as microcomputed tomography. A process window with different rolling tools and rolling paths has been identified
and analysed. The results show clearly advantageous properties regarding an improved surface roughness,
with a higher densification gradient in the first perimeter tracks of the FFF extrusion strategy as well as sharper
corners being realized.Mechanical Engineerin
