Distortion modeling of SL parts by classical lamination theory

Purpose - In stereolithography (SL), the total exposure absorbed by photopolymer is variable and is a function of height. This phenomenon causes heterogeneous properties and develops residual stresses during process. Consequently, a pronounced deformation occurs especially when small and more intricate objects are fabricated. The purpose of this paper is to predict this deformation when miniature and complicated parts are fabricated. Design/methodology/approach - In this paper classical lamination theory is employed to model mechanical properties of layers, layers shrinkage and residual stress growth during SL process. Distortion is predicted based on the developed model. Findings - Results show that final distortion is proportional to part thickness and it increases exponentially as parts thickness or layers thickness decrease. Practical implications - To verify the results, several test pieces were built with SLA 5000 machine and SOMOS 1 1120 resins. Their distortions were measured with video measuring machine (VMM-3020D machine). The estimation agrees very well with the experimental results (less than 10 per cent error). Originality/value - The paper considers the heterogeneous properties of SL parts during fabrication process; an item which was ignored in previous researches. This theoretical and experimental study provides useful information about estimation of deformation of SL parts after building. This information helps the SL machine user to select the best parameters when fabricating miniature and intricate features, especially for biomechanics parts.