Investigation of Low Force Stereolithography Using Selected Applications and Recommendations for a Better Workflow

Since additive manufacturing in general, and also low force stereolithography technology, faces a knowledge gap that is one of the biggest limiting factors for its general adoption, this thesis aimed to close this information gap by investigating some selected advanced applications. In this respect, various scientific questions were addressed regarding the effects of different part orientations, the feasibility and requirements of manufacturing metric internal and external threads, and the approach of printing objects on top of each other. Moreover, stereolithography requires working with toxic substances, which makes safety and cleanliness important aspects. Therefore, the second objective of this thesis was to improve the workflow for the 3D printing laboratory at Lapland University of Applied Sciences. Firstly, to investigate the effects of different part orientations, two different objects were produced at different angles to analyse the effects on material consumption, print time and overall visual quality. Secondly, by producing different-sized metric internal and external threads, the feasibility and necessary scaling factors were determined and thirdly, the possibility and effects of stacked printed objects were investigated by using two different methods and object types. All practical printing tests were carried out using Formlabs' Form 3 printer. Furthermore, all workflow recommendations were developed based on own experience within this thesis. The wide-ranging results of this thesis imply that part orientation has a substantial effect on earlier mentioned parameters and is best when the object surface area facing the build platform is kept to a minimum. Furthermore, M12 to M4 threaded screws and nuts are possible to print when considering investigated scaling factors and printing objects on top of each other was found as feasible but not as economic. Regarding workflow improvements, some setup upgrades and a contamination concept was introduced, and the complete improved workflow was re-defined