STEREOLITHOGRAPHY
What is Stereolithography (SLA)?
• Stereolithography Apparatus (SLA) is a liquid-
based process which builds parts directly from
CAD software.
• SLA uses a low-power laser to harden photo-
sensitive resin and achieve polymerization.
• A hopper full of the resin lies under a laser
which uses its beam to harden the part in layers
a Min. of 0.001” (0.0254 mm) and up to 150
lbs. (68.03 kg) Part weight.
• Parts can reach a Max. size of 20”x20”x23”.
The Stereolithography Process
Stereolithography: Apparatus
Stereolithography
Stereolithography
Pre-process:
• Orient part.
• Choose slice thickness.
• Slice parts and plan supports.
Stereolithography
Process:
• Building platform (stage wise) just below
liquid resin surface.
• Smooth surface is ascertained using a re-
coater blade.
• Scanning the outline of the current slice,
and loosely hatch part interiors with the
laser.
• Lower the build platform for the next layer.
Stereolithography
Post-process:
• Raise the part and drain out liquid.
– (except liquid trapped by loose hatch)
• Break off supports.
• Rinse in isopropanol and water.
• Dry with air hose.
• Post-cure (strengthen) in UV oven.
Stereolithography
Characteristics:
• Slow process
• Supports must be removed by hand
• Lab environment necessary (gas molecules!)
• Needs trained operator
• Laser lasts 2000hrs, costs $20,000!
• Little material choice, ($700 per gallon)
• Parts can be brittle, fragile
Stereolithography
Characteristics (cont.):
• High accuracy
– Layer thickness 0.001 - 0.006”
– Minimum feature size 0.003 - 0.012”
• Large build volume
– Up to 20 x 20 x 23”
Stratasys Connex machine for their RGD515
material
Principle
• Part are built from a photo curable liquid resin
that cures when exposed to a laser beam
(basically, undergoing photo-polymerization
process) which scans across the surface of the
resin.
• The building is done layer by layer, each layer
being scanned by the optical scanning system and
controlled by an elevation mechanism which
lowers at the completion of each layer.
Photopolymers
• Many types of liquid photopolymers can be solidified by
exposure to electro-magnetic radiation, including
wavelengths in the gamma rays, X-rays, UV and visible
range, or electron-beam (EB).
• The majority of photopolymers used in the commercial
RP systems, including 3D Systems’ SLA machines are
curable in the UV range. UV-curable photopolymers are
resins which are formulated from photoinitiators and
reactive liquid monomers.
• There are a large variety of them and some may contain
fillers and other chemical modifiers to meet specified
chemical and mechanical requirements.
Photopolymerization
• Polymerization is the process of linking small
molecules (known as monomers) into chain-like
larger molecules (known as polymers).
• When the chain-like polymers are linked further
to one another, a cross-linked polymer is said to
be formed.
• Photopolymerization is polymerization initiated
by a photochemical process whereby the starting
point is usually the induction of energy from the
radiation source
Benefits of SLA
• Crisp, highly-detailed • Test Product
pieces. • Error Identification
• Speed of delivery • Improves Design
(usually 2-3 days).
• Rapid Manufacturing
• Tolerances within
.005"/inch.
• Saves Money & Time.
SLA Materials
Courtesy : Gibson, 2013, Thomson, 2018 (Springer)
Cost
• Cost of the material: The resin costs as much as
$600-$800 (>INR 57,000/ per gallon. (For a
20”x20”x23” cube that’s 39.8 gallons (150 litres)!
…$27,860 (INR 19, 85, 256))
• Post processing Requirements:
– Careful practices are required to work with the
resins.
– Framework must be removed from the finished
part.
– Alcohol baths followed by Ultraviolet ovens are
used to clean and cure the parts.
Applications of SLA Technology
• Aesthetic & Conceptual models.
• Parts requiring Detail & Accuracy.
• Master patterns for castings and secondary
processes.
Courtesy : Gibson, 2013, Thomson, 2018 (Springer)
Courtesy : Gibson, 2013, Thomson, 2018 (Springer)
Comparison Between SLA and FDM
(Fused Deposition Modeling)
• Precision of Dimensions
Courtesy : Gibson, 2013, Thomson, 2018 (Springer)
• Surface Quality
Roughness of the untreated surfaces of SLA
components >103 better than FDM
components.
• Dimension Change with Humidity
Permanent changes in the dimensions occur
when SLA components are stored under
humid conditions.