Related Experiment Video
Updated: Nov 22, 2025
09:17
Surrogate Model Development for Digital Experiments in Welding
Published on: March 28, 2025
1.4K
Voxel based method for predictive modelling of solidification and stress in digital light processing based additive
Andrew Reid1, Joseph C Jackson1, J F C Windmill1
1University of Strathclyde, Centre for Ultrasonic Engineering, Glasgow, UK. andrew.reid@strath.ac.uk.
Soft Matter
|January 7, 2021
Summary
This study introduces a voxel-based model to predict material solidification and stress in digital light processing 3D printing. The method accurately forecasts polymerization and stress, crucial for micro-scale systems.
Area of Science:
- Materials Science
- Chemical Engineering
- Mechanical Engineering
Background:
- Additive manufacturing (AM) offers rapid prototyping, but complex photopolymerization processes in 3D printing are challenging to model predictively.
- Accurate prediction of stress is vital for 3D printing micro-scale electrical and mechanical systems, such as resonators and conductive layers.
- Current iterative workflows often outweigh the appeal of complex predictive modeling for photopolymerization during part construction.
Purpose of the Study:
- To develop and validate a predictive model for solidification and stress in digital light processing (DLP) 3D printing.
- To enable accurate prediction of the degree of polymerization and resulting mechanical stress throughout the 3D printing process.
- To provide a computational tool for optimizing print parameters and post-processing for micro-scale AM applications.
Main Methods:
- A voxel-based, multi-layer model was employed to simulate the degree of polymerization at each stage of the DLP 3D printing process.
- Printed cantilevers were utilized as a calibration method to quantify stress arising from polymerization fronts and gradients.
- The model integrates computer-aided design (CAD) data to predict stress and solidification outcomes.
Main Results:
- The developed model demonstrates good predictive accuracy for both material solidification and stress generation during DLP 3D printing.
- Calibration using printed cantilevers effectively correlated model predictions with experimental stress measurements.
- The model successfully predicted stress and solidification based on input CAD files.
Conclusions:
- The proposed voxel-based model offers a viable and accurate method for predicting solidification and stress in DLP 3D printing.
- This predictive capability is essential for advancing the design and fabrication of micro-scale components using additive manufacturing.
- The approach facilitates informed adjustments to print parameters and post-processing for improved part quality and reliability.
