CME339 ADDITIVE MANUFACTURING

IIIrd YEAR/ Vth SEMESTER

[Link],
Professor,
Centre for Additive Manufacturing,
Department of Mechatronics Engineering,
Chennai Institute of Technology,
Chennai - 600069
UNIT III VAT POLYMERIZATION AND DIRECTED
ENERGY DEPOSITION

Photo polymerization: Stereolithography Apparatus (SLA)- Materials

-Process – top down and bottom up approach - Advantages -

Limitations - Applications. Digital Light Processing (DLP) - Process -

Advantages - Applications. Continuous Liquid Interface Production

(CLIP)Technology. Directed Energy Deposition: Laser Engineered Net

Shaping (LENS)- Process - Material Delivery - Materials -Benefits -

Applications
 Photo polymerization
• Photo polymerization is a chemical process in which a liquid
monomer is transformed into a solid polymer under the influence
of light.
• The process is commonly used in various industries, including 3D
printing, coatings, adhesives, and dental applications.
• Photo polymerization is particularly popular in 3D printing, where
it is used in a technique called stereo lithography.
• In this process, a liquid resin containing photo initiators and
monomers is selectively exposed to light in a pattern that
corresponds to the desired object's shape.
• The exposed areas undergo photo polymerization and solidify,
while the unexposed areas remain liquid and can be drained away.
• This layer-by-layer process allows the creation of complex 3D
structures with high precision.
 Types of Photo polymerization
1. Stereolithography (SLA):.

2. Digital Light Processing (DLP):

3. Masked Stereolithography (MSLA):.

4. PolyJet:

5. Continuous Liquid Interface Production (CLIP):

6. Digital Material Jetting (DMJ):

7. Micro-Stereolithography (µSLA):
 Stereolithography (SLA)
• Stereolithography (SLA) is an industrial 3D printing process used

to create concept models, cosmetic prototypes, and complex

parts with intricate geometries in as fast as 1 day.

• A wide selection of materials, extremely high feature resolutions,

and quality surface finishes are possible with SLA.

• SLA 3D printing is primarily used for:
– parts requiring high accuracy and features as small as 0.002 in.
– good surface quality for cosmetic prototypes
– form and fit testing
• SLA can stand for various things depending on the context,

but one common meaning is "Stereolithography" or

"Stereolithography Apparatus." Stereolithography is a 3D

printing or additive manufacturing technology that works

based on a principle called photopolymerization.

SLA Process
 SLA Process
1. Digital Model Preparation:
Process Specification: The 3D model is created or imported using CAD software. The model must
be watertight and error-free to ensure accurate printing.
2. Slicing:
Process Specification: Specialized slicing software is used to divide the 3D model into thin,
horizontal layers (slices). The layer thickness is typically between 0.05 to 0.15 millimeters,
depending on the desired resolution.
3. Resin Selection:
Process Specification: Choosing the appropriate photopolymer resin is crucial. Resin properties like
color, flexibility, transparency, and mechanical strength should match the intended use of the final
object.
4. Resin Vat Setup:
Process Specification: The resin vat or tank is filled with the selected liquid photopolymer resin.
Proper resin handling and disposal procedures are followed due to the chemical nature of the
resin.
5. Build Platform Positioning:
Process Specification: The build platform, which can move up and down, is positioned at the
bottom of the resin vat, typically submerged in the liquid resin.
6. Layer-by-Layer Printing:
Process Specification:
1. A UV laser or other suitable light source is used to selectively solidify the resin layer by layer.
2. The laser power and exposure time are controlled to ensure proper curing and adhesion between layers.
 SLA Process
7. Platform Movement:
Process Specification: After each layer is solidified, the build platform moves upward by a distance equal to the
layer thickness. This allows for the creation of the next layer.
8. Resin Re-coating:
Process Specification: After each layer is completed, the resin vat automatically re-coats the surface with a thin
layer of fresh liquid resin. This ensures a clean and level surface for the next layer.
9. Repeat Printing Process:
Process Specification: Steps 6 to 8 are repeated for each subsequent layer until the entire object is 3D printed.
The number of layers depends on the height of the object and the chosen layer thickness.
10. Post-Processing:
Process Specification:
1. Once printing is complete, the object is carefully removed from the build platform.
2. Excess resin may be drained or wiped off.
3. Post-curing may be necessary by exposing the object to additional UV light to ensure complete hardening.
4. Support structures, if used, are removed, and the object may undergo further finishing processes like sanding or polishing.

11. Quality Control:

Process Specification: The final object is inspected for accuracy, surface finish, and dimensional precision. Any
defects or imperfections are addressed as needed.
12. Final Handling and Storage:
Process Specification: The finished 3D printed object is properly cleaned, and any residual chemicals or resin are
thoroughly removed. It's then stored or used for its intended purpose.
 Advantages of SLA process
• Smooth Surface Finish: SLA produces parts with a smooth surface finish, often eliminating the need for extensive post-processing. This
makes it ideal for applications where aesthetics matter.
• Wide Material Selection: SLA supports a wide range of photopolymer resins with various properties. These resins can be tailored to meet
specific requirements, such as flexibility, transparency, heat resistance, or biocompatibility.
• Complex Geometries: SLA is capable of creating complex and intricate geometries that may be challenging for other 3D printing methods.
It excels at producing parts with fine details, undercuts, and internal channels.
• Quick Turnaround: SLA is a relatively fast 3D printing technology, and it can produce parts quickly compared to some other additive
manufacturing methods. This rapid turnaround time is valuable for prototyping and small-scale production.
• Minimal Material Waste: SLA is an additive process, meaning it adds material only where needed. This results in minimal material waste,
making it an environmentally friendly option.
• Support Structures: SLA printers can generate support structures automatically or with minimal manual intervention. These supports help
maintain the integrity of overhanging or complex features during printing.
• High Resolution and Accuracy: SLA printers are capable of maintaining dimensional accuracy and producing consistent parts, which is
crucial for applications like dentistry, jewelry, and engineering prototypes.
• Biocompatible Resins: SLA can use biocompatible resins, which are suitable for creating medical devices and dental applications. These
resins have been approved for use in contact with the human body.
• Prototyping and Rapid Iteration: SLA is widely used for prototyping and iterative design processes. It allows designers and engineers to
quickly create physical models and test their concepts, leading to faster product development.
• Minimal Post-Processing: Parts produced using SLA typically require less post-processing, such as sanding or painting, compared to other
3D printing methods.
• Small Form Factor Printers: SLA printers are available in various sizes, including desktop models, making them accessible to a wide range
of users, from hobbyists to professionals.
 Disadvantages of SLA process
• Material Limitations: SLA primarily uses liquid photopolymer resins. While there is a variety of resins available,
the material options are not as extensive as those in other 3D printing processes like Fused Deposition Modeling
(FDM) or Selective Laser Sintering (SLS).
• Post-Processing Requirements: While SLA parts generally have a smooth surface finish, they may require post-
processing to remove support structures, sand, paint, or apply additional finishes. This can add time and effort to
the production process.
• Resin Handling: Photopolymer resins used in SLA can be messy and require careful handling. Exposure to
uncured resin can be harmful to the skin and eyes, necessitating safety precautions and proper disposal
procedures.
• Limited Build Volume: SLA printers tend to have smaller build volumes compared to some other 3D printing
technologies. This can be a limitation when attempting to create large parts or multiple parts in a single build.
• Layer Bonding: While SLA can produce highly detailed parts, the layer bonding in SLA prints may not be as strong
as in other processes like FDM. This can affect the mechanical properties of the final part.
• UV Sensitivity: SLA-printed parts may be sensitive to UV light and can degrade or discolor when exposed to
prolonged sunlight or certain environmental conditions.
• Expense: SLA printers and materials can be more expensive than other 3D printing options, both in terms of
initial purchase and ongoing material costs. High-quality SLA printers can have a significant price tag.
• Support Structures: While SLA can generate support structures automatically, they can be challenging to remove,
especially in complex geometries. This can require additional time and effort.
• Limited Material Compatibility: Not all photopolymer resins are compatible with SLA printers. Users must ensure
that the chosen resin is suitable for their specific SLA printer model.
• Toxic Emissions: The resin curing process in SLA emits volatile organic compounds (VOCs) and can produce
unpleasant odors. Adequate ventilation is necessary when using SLA printers in enclosed spaces.
• Durability: SLA-printed parts may not be as durable or heat-resistant as parts produced using other 3D printing
 Applications of SLA
• Jewelry and Accessories: SLA's ability to produce intricate and delicate designs makes it popular in the jewelry industry for
creating detailed pieces like rings, pendants, and custom accessories.
• Dental and Orthodontic Models: SLA is used to create highly accurate dental and orthodontic models for procedures like crown
and bridge work, aligner production, and surgical planning.
• Medical Devices: SLA is employed to fabricate prototypes and functional components for medical devices, such as custom
prosthetics, surgical guides, and models for preoperative planning.
• Aerospace and Aviation: SLA is used for creating scale models, prototypes of aircraft components, and intricate models for wind
tunnel testing and aerodynamic analysis.
• Architectural Models: Architects use SLA to create detailed scale models of buildings, landscapes, and urban planning projects to
help visualize designs and communicate ideas to clients.
• Consumer Goods: SLA is used for producing consumer products with intricate designs, such as smartphone cases, small
appliances, decorative items, and personalized gifts.
• Automotive Prototyping: SLA helps in the rapid prototyping of automotive components and accessories, allowing engineers to
assess fit, form, and function before finalizing designs.
• Art and Sculpture: Artists and sculptors use SLA to create intricate and detailed sculptures, figurines, and art pieces that would
be challenging to produce through traditional methods.
• Microfluidics and Biotechnology: SLA is used to fabricate microfluidic devices, lab-on-a-chip systems, and other intricate
structures for biotechnology and medical research.
• Customized Wearables: SLA is employed to create custom-fit wearables, such as hearing aids, eyeglass frames, and orthopedic
supports.
• Educational Models: SLA-produced models and prototypes are used in educational settings to enhance learning in fields such as
biology, engineering, architecture, and more.
• Mold Making and Tooling: SLA can be used to create patterns for investment casting and as master patterns for silicone molds
used in traditional manufacturing processes.
• Rapid Tooling: SLA can be used for producing prototype tooling and molds for low-volume production runs, helping to reduce
lead times for manufacturing.
• Electronics Enclosures: SLA is utilized to create custom enclosures for electronic devices, allowing for precise fit and unique
designs.