Optimization of Dimensional Accuracy and Surface Roughness of SLA Patterns and SLA-Based IC Components

Aishabibi Mukhangaliyeva, Damira Dairabayeva, Asma Perveen, Didier Talamona

Research output: Contribution to journalArticlepeer-review

Abstract

Rapid investment casting is a casting process in which the sacrificial patterns are fabricated using additive manufacturing techniques, making the creation of advanced designs possible. One of the popular 3D printing methods applied in rapid investment casting is stereolithography because of its high dimensional precision and surface quality. Printing parameters of the used additive manufacturing method can influence the surface quality and accuracy of the rapid investment cast geometries. Hence, this study aims to investigate the effect of stereolithography printing parameters on the dimensional accuracy and surface roughness of printed patterns and investment cast parts. Castable wax material was used to print the sacrificial patterns for casting. A small-scale prosthetic biomedical implant for total hip replacement was selected to be the benchmark model due to its practical significance. The main results indicate that the most significant stereolithography printing parameter affecting surface roughness is build angle, followed by layer thickness. The optimum parameters that minimize the surface roughness are 0.025 mm layer thickness, 0° build angle, 1.0 support density index, and across the front base orientation. As for the dimensional accuracy, the optimum stereolithography parameters are 0.025 mm layer thickness, 30° build angle, 0.6 support density index, and diagonal to the front base orientation. The optimal printing parameters to obtain superior dimensional accuracy of the cast parts are 0.05 mm layer thickness, 45° build angle, 0.8 support density index, and diagonal to the front model base orientation. With respect to the surface roughness, lower values were obtained at 0.025 mm layer thickness, 0° build angle, 1.0 support density index, and parallel to the front base orientation.

Original languageEnglish
Article number4038
JournalPolymers
Volume15
Issue number20
DOIs
Publication statusPublished - Oct 2023

Keywords

  • dimensional accuracy
  • optimization
  • printing parameters
  • rapid investment casting
  • stereolithography
  • surface roughness
  • Taguchi

ASJC Scopus subject areas

  • General Chemistry
  • Polymers and Plastics

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