Novel stereolithography system for small size objects

Abstract

PurposeTo satisfy the demands for rapid prototyped small‐size objects with intricate microstructures, a high‐resolution stereolithography (SL) system is developed.Design/methodology/approachThis novel SL system consists of a single mode He‐Cd laser, an improved optical scanning system, a novel recoating system and a control system. The improved optical system consists of a beam expander, an acoustic‐optic modulator, a galvanometric scanner and an F‐θ lens; the recoating system consists of roller pump, resins vat with an integrated high‐resolution translation stage and part building platform and a scraper. Experimental studies were performed to investigate the influences of building parameters on the cured line width and depth.FindingsWith the SL system, a laser light spot with a diameter of 12.89 μm on the focal plane and resin layers with a thickness of 20 μm have been obtained. The experimental results indicate that cured depth and width increase with the ratio of laser power to scanning speed, and cured line with a width of 12 μm and a depth of 28 μm was built, which showed the capability building microstructures with this new SL system.Research limitations/implicationsThe building area limited to 65 × 65 mm, is smaller than that of current SL system.Practical implicationsSmall objects with intricate microstructures can be fabricated with the SL system.Originality/valueThe high‐resolution SL system provides a solution to the problem that has hampered the progress of SL process into a high resolution ranges below 75 μm.