Reducing the surface deviation of stereolithography using in‐process techniques

Builds on previous research by the authors to establish a mathematical representation of the surface roughness of stereolithography (SL) parts. It is the intention of the research to use this modelling technique as a design tool for defining optimum build orientation and planning post‐process finishing operations. During the development of this model, a number of in‐process attributes inherent in SL were seen to affect surface deviation. Most notably the phenomenon known as “print‐through” on down‐facing planes produces a build orientation envelope of very smooth surfaces. Although capable of providing low roughness over some 50°, print‐through smoothing cannot easily be extended to other angles, hence complementary processes for surface smoothing must be developed. Discusses a number of possible solutions, showing how the generation of a meniscus between layers can prove beneficial in reducing SL surface roughness, hence reducing the need for lengthy manual finishing operations.