Stereolithography

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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 0.07mm
good surface quality for cosmetic prototypes
form and fit testing

How Stereolithography 3D Printing Works

As with any 3D printing technique, a 3D digital file is required. This can be obtained via CAD software (SolidWorks, Sculpt or SelfCAD for example). These files (usually STL files), are to a slicer, which cuts the model into thin layers to print. The instructions are then sent to the 3D printer.

Stereolithography machines contain a resin tray, a mobile platform (Z axis), a scraping system (X axis), a UV laser, focusing optics and a mirror galvanometric (X and Y axes).

The laser beam sweeps the surface of the liquid resin according to the digital 3D model supplied to the printer. After one layer has been solidified, the platform descends a level. The next section is then solidified. There are as many printing cycles as there are layers necessary to obtain the complete volume of the piece.

On some models of SLA machines (like at Formlabs for example), the production of the piece is done in reverse. The platform is instead submerged in the resin tray while the laser acts from bottom to top.

Post-printing

Once the printing is finished, a step of cleaning the room, using a solvent (usually isopropyl alcohol also called isopropanol), is necessary in order to remove the excess non-solidified resin. Unlike other techniques such as Selective Laser Sintering (SLS), Fused Deposition Material (FDM), and PolyJet 3D printing, UV post-treatment is usually required to finalize the photo-polymerization process to maximize the strength of the material.

As with fused deposition technology, SLA uses scaffolds when printing complex shapes. In the manner of a scaffolding, they allow to support the parts that dash in the vacuum. They are removed during post-processing.

Stereolithography technology offers a slightly vitreous surface finish but is generally superior to FDM or SLS processes (for the same layer thickness). It is not uncommon that the different layers of printing are barely visible. However, few colors are available in SLA.

Applications offered by Stereolithography

SLA is more often used for prototyping in all areas of the industry because of its speed, but depending on the quality of the printer, it is also possible to obtain parts that are immediately functional. SLA is also used for the production of injection molds or foundries, particularly in the world of jewellery and dentistry.

Lost wax casting is an example of an indirect manufacturing process using stereolithography. This millenary technique now rests on the 3D printing an accurate replica of the final model (also called jewelery master) in a calcinable wax. Once printed, it is wrapped in a refractory material, creating the mold. A molten metal is then poured into the mold. The metal part can then be used after being removed from the mold.

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