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LIQUID BASED RAPID PROTOTYPING SYTEMS
Most liquid based rapid proto typing systems build

parts in a vat curable resin, which cures or
solidifies under the effect of exposure to laser
radiation, usually in UV range.
The laser cures the resin near surface, forming a
hardening layer.
When a layer of a part is formed, it is lowered by

an elevation control system to allow the next layer
of resin to be similarly formed over it.
This continues until the entire part is

completed.
The vat can then be drained out and the part is
removed for further processing.
There are variations to this technique by the
various vendors and they are dependent on the
type of light or laser, method of scanning or
exposure, type of liquid resin, type of elevation
and optical system used.
Stereolithography
Stereo – three dimensions
Lithography – printing
Started with acrylic resins in the early 1980’s
Epoxy resins are more common now
Very good accuracy
UV Laser cure
Relatively slow speed
Newer resins with improved properties
3
Stereolithography (SLA)
SLA was pioneered by Chuck Hull in Current market leaders
the mid-1980s (see picture below). - 3D Systems
Hull founded 3D Systems to - Sony
commercialize its new manufacturing
process.
3D Systems iPro 9000 XL

4
What is Stereolithography (SLA)?
A "rapid-prototyping" process which produces a physical, three
dimensional object from a 3D CAD file.
• Fabricating a solid plastic part out of a

photosensitive liquid polymer using a directed
laser beam to solidify the polymer
• Part fabrication is accomplished as a series of

layers - each layer is added onto the previous
layer to gradually build the 3-D geometry
Stereolithography (SLA)
1. A structure support base is
positioned on an elevator structure
and immersed in a tank of liquid
photosensitive monomer, with only
a thin liquid film above it
2. A UV laser locally cross-links the
monomer on the thin liquid film
above the structure support base
3. The elevator plate is lowered by a
small prescribed step, exposing a
fresh layer of liquid monomer, and
the process is repeated A suitable photosensitive
4. At the end of the job, the whole part polymer must be very
transparent to UV light in
is cured once again after excess
uncured liquid form and very
resin and support structures are absorbent in cured solid form,
removed to avoid bleeding solid features
into the layers underneath the
current one being printed. 6
Stereolithography
Stereolithography: (1) at the start of the process, in which the

initial layer is added to the platform; and (2) after several
layers have been added so that the part geometry gradually
takes form.
Principle:
The SLA process is based on the following
principles.
1. Parts are built from a photo-curable liquid
resin that cures when exposed to a laser beam
which scans across the surface of the resin.
2. 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
There are many types of liquid photopolymers that

can be solidified by exposure to electro-magnetic
radiation, including wavelengths in the gamma
rays, X-rays, UV and visible range.
The vast majority of photopolymers used in the
commercial RP systems are curable in the UV
range.
UV curable photo polymers are resins which are

formulated from photo iniators and reactive liquid
monomers.
Photo polymerization
The process through which photopolymers are
cured is called as photo polymerization process.
It is the process of linking small molecules

(monomers) into chain like larger molecules
(polymers).
When the chain like polymers are linked

further to one another, a cross linked polymer
is said to be formed.
Photo polymerization is polymerization initiated
by a photochemical process whereby the
starting point is usually the induction of energy
from the radiation source.
Layering Technology, Laser and Laser scanning:
Almost all RP systems use layering technology in the creation of
prototype parts. The basic principle is the availability of
computer software to slice a CAD model into layers and
reproduce it in an output device like a laser scanning system.
The layer thickness is controlled by a precision elevation
mechanism. It will correspond directly to the slice thickness of
the computer model and the cured thickness of the resin.
The important component of the building process is the laser
and its optical scanning system. The key to the strength of the
SLA is its ability to rapidly direct focused radiation of
appropriate power and wavelength onto the surface of the
liquid photopolymers resin, forming patterns of solidified
photopolymer according to the cross-sectional data generated
by the computer.
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Advantages
 Round the clock operation without much

attention.
 Good user support
 Build volumes. From small to large size to suit

the needs.
 Good Accuracy
 Good surface finish. Best among many RP

technologies.
 Wide range of materials. For general purpose

Disadvantages
Requires support
structures
Requires post
processing
Requires post curing

Applications:
Models for conceptualization, packaging and
presentation
Prototypes for design, analysis, verification and

functional testing
Parts for prototype tooling and low volume

production tooling
Patterns for investment casting, sand casting and

molding
Tools for fixture and tooling design, and

production tooling.
A part produced by stereolithography (photo
courtesy of 3D Systems, Inc.).
Conclusions
 Stereolithography is a liquid based RP process. Fast and
effective.
 Material: Photosensitive resin
 Tool: Low powered laser (UV light)
 Process: Curing the photo polymer through photo

polymerization process.
 Can be applied to almost every industry, including oil

refining, petrochemical, power, marine, and municipal
 Saves time, money, allows speed delivery, and improve

designs.

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LIQUID BASED RAPID PROTOTYPING SYTEMS

Most liquid based rapid proto typing systems build

When a layer of a part is formed, it is lowered by

This continues until the entire part is

3D Systems iPro 9000 XL

• Fabricating a solid plastic part out of a

• Part fabrication is accomplished as a series of

Stereolithography: (1) at the start of the process, in which the

2. The building is done layer by layer, each

There are many types of liquid photopolymers that

UV curable photo polymers are resins which are

It is the process of linking small molecules

When the chain like polymers are linked

 Round the clock operation without much

 Good user support

 Build volumes. From small to large size to suit

 Good surface finish. Best among many RP

 Wide range of materials. For general purpose

Requires post curing

Prototypes for design, analysis, verification and

Parts for prototype tooling and low volume

Patterns for investment casting, sand casting and

Tools for fixture and tooling design, and

 Material: Photosensitive resin

 Tool: Low powered laser (UV light)

 Process: Curing the photo polymer through photo

 Can be applied to almost every industry, including oil

 Saves time, money, allows speed delivery, and improve

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