An investigation on energy consumption and part quality of stereolithography apparatus manufactured parts

Jizhuang Hui, Zhiqiang Yan, Jingxiang Lv, Yongsheng Liu, Kai Ding, Felix T.S. Chan

Research output: Journal article publicationJournal articleAcademic researchpeer-review

Abstract

Purpose: This paper aims to investigate the influences of process parameters on part quality, electrical energy consumption. Moreover, the relationship between part quality and energy consumption of UTR9000 photosensitive resin fabricated by stereolithography apparatus (SLA) was also assessed. Design/methodology/approach: Main effect plots and contour maps were used to analyze the interactions and effects of various parameters on energy consumption and part quality, respectively. Then, a growth rate was used defined as the percentage of the value of energy consumption (or the part quality) of the sample compared to the minimum value of the energy consumption (or the same part quality), to jointly analyze relationships between part quality and energy consumption on a specific process parameter. Findings: The part qualities can be improved with increased energy consumption via adjusting layer thickness, without further increasing energy consumption through adjusting laser power, over-cure and scanning distance. Energy consumption can be highly saved while slightly decreasing the tensile strength by increasing layer thickness from 0.09 mm to 0.12 mm. Energy consumption and surface roughness can be decreased when setting laser power near 290 mW. Setting an appropriate over-cure of about 0.23 mm will improve tensile strength and dimensional accuracy with a little bit more energy consumption. The tensile strength increases nearby 5% at a scanning distance of 0.07 mm compared to that at a scanning distance of 0.1 mm while the energy consumption only increases by 1%. Originality/value: In this research, energy consumption and multiple part quality for SLA are jointly analyzed first to accelerate the development of sustainable additive manufacturing. This can be used to assist designers to achieve energy-effective fabrication in the process design stage.

Original languageEnglish
Pages (from-to)52-67
Number of pages16
JournalRapid Prototyping Journal
Volume28
Issue number1
DOIs
Publication statusPublished - 3 Jan 2022

Keywords

  • Additive manufacturing
  • Coordination optimization
  • Energy consumption
  • Joint analysis
  • Part quality
  • Stereolithography
  • Top-bottom stereolithography apparatus

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

Cite this