Numerical Analysis of Stereolithography Process using the Finite Element Method

Abstract

In present highly competitive environment need for better design features along with reduced costing has become very important. Rapid Prototyping also referred to as solid free-form manufacturing, computer automated manufacturing, and layered manufacturing has obvious use as a vehicle for visualization. In addition, RP models can be used for testing, such as when an airfoil shape is put into a wind tunnel. Rapid tooling arises from rapid prototyping, such as silicone rubber molds and investment casts. Rapid manufacturing arises from rapid prototyping to use rapid prototyping systems to directly produce parts which are functional end-use item with the advantage that there is no need for tooling. The rapid prototyping (RP) process is the fastest and most feasible method for prototype construction. However, with the use of any material or build method the phenomenon of volume shrinkage is unavoidable. It is known that volume shrinkage and curl distortion are the major causes that lead to poor accuracy of the built prototype. Subsequently, in order to improve the precision of dimension and volume shrinkage, more expensive equipment is used on the market. Also, it is expensive and inefficient to obtain better process parameters through trail and error in the RP process. In order to improve the precision of dimension, reduce the processing cost and the frequency of trail and error, this study first induces the concept of computer aided engineering (CAE) into the processing of RP, which uses a finite element simulation code to simulate the photopolymerization process, so as to obtain the distortion data. Besides, it is believed that this research method can be promoted to other materials or build methods in RP fabrication.