Abstract
The leading-edge bulge refers to the slurry surface bulge at the foremost edge of the solidified part during the recoating process in stereolithography (SL). This effect leads to dimensional errors of the products and even the collision between the blade and the part being built, especially for ceramic SL using high-viscosity slurries. In this paper, a numerical model on the recoating process in top-down SL shaping systems was developed adopting fine layer thickness and non-Newtonian slurry. With the verification of experiments, the results showed that although the leading-edge bulge occurs at the transition region between the recoated layer and the vat level, it is not much affected by the level change of these two regions. The inward inclination at the rear side of the blade was found to significantly reduce the error of the leading-edge bulge, which could be attributed to the decline of the slurry that is attached to the rear side of the blade during the recoating process.
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