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

Area of Science:

• Additive Manufacturing
• Materials Science
• Biomedical Engineering

Background:

• Rapid investment casting enables complex geometries using additive manufacturing.
• Stereolithography (SLA) is favored for its precision and surface finish in pattern fabrication.
• Printing parameters critically influence the quality of SLA-produced patterns and final cast parts.

Purpose of the Study:

• To investigate the impact of SLA printing parameters on dimensional accuracy and surface roughness.
• To identify optimal parameters for producing high-fidelity sacrificial patterns for investment casting.
• To enhance the quality of cast biomedical implants, specifically hip replacements.

Main Methods:

• Utilized stereolithography (SLA) to print castable wax patterns.
• Selected a small-scale prosthetic hip implant as the benchmark model.
• Analyzed the effects of build angle, layer thickness, support density, and orientation on pattern and cast part quality.

Main Results:

• Build angle and layer thickness were the most influential parameters for surface roughness.
• Optimal parameters for minimizing surface roughness: 0.025 mm layer thickness, 0° build angle.
• Optimal parameters for dimensional accuracy varied, with specific settings for pattern vs. cast part accuracy.

Conclusions:

• SLA parameter optimization is crucial for achieving desired dimensional accuracy and surface roughness in investment casting.
• Specific parameter sets were identified to minimize surface roughness and maximize dimensional accuracy for biomedical implant patterns and castings.
• Findings provide a basis for refining SLA processes in the production of high-quality cast biomedical devices.