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Rapid Prototyping

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Stereolithography

Stereolithography is an additive fabrication process utilizing a vat of liquid UV-curable photopolymer "resin" and a UV laser to build parts a layer at a time. On each layer, the laser beam traces a part cross-section pattern on the surface of the liquid resin. Exposure to the UV laser light cures, or, solidifies the pattern traced on the resin and adheres it to the layer below.

After a pattern has been traced, the SLA's elevator platform descends by a single layer thickness, typically 0.05 mm to 0.15 mm (0.002" to 0.006"). Then, a resin-filled blade sweeps across the part cross section, re-coating it with fresh material. On this new liquid surface the subsequent layer pattern is traced, adhering to the previous layer. A complete 3-D part is formed by this process. After building, parts are cleaned of excess resin by immersion in a chemical bath and then cured in a UV oven.

Stereolithography requires the use of support structures to attach the part to the elevator platform and to prevent certain geometry from not only deflecting due to gravity, but to also accurately hold the 2-D cross sections in place such that they resist lateral pressure from the re-coater blade. Supports are generated automatically during the preparation of 3-D CAD models for use on the stereolithography machine, although they may be manipulated manually. Supports must be removed from the finished product manually; this is not true for all rapid prototyping technologies.

StereoLithography

StereoLithography is one of the most common rapid prototyping (RP) systems. The system utilizes a computer controlled UV laser beam to harden a photocurable liquid resin to produce 3-D copies of CAD models. The SLA computer utilizes an (.STL) file format output from professional solid modeling software programs.

Stereolithography

Stereolithography is the first RP process and is still the most utilized of all types of Rapid Prototyping being the most accurate with finest surface finishes.

Finish Options

Finish Options

Stereolithography (SLA) is the finest of all types of Rapid Prototyping. The process accurately produces fine details in design or engineering review parts, master patterns can be painted and "trade show" can have coatings such as textured finishes for "consumer product" like look.

Levels of finish for SLA parts come in 5 types:

Class 1A Pattern Level: Parts are taken off the tray and cured with minimal finish, removing the supports for quickest turnaround and lowest cost.

Class 2A Engineering Review: Class 2A Engineering Review: After curing and support removal, parts are sanded lightly and bead blasted for an accurate finish. Layering marks will still be apparent all surfaces and more apparent on curved surfaces. This finish is suitable for fit and form check. This is the industry standard finish and 90% of all pats sold..

Class 3A Presentation Model: Parts are sanded to a smooth finish on the outside. Primer is optional and must be specified in the RFQ, primer cost is not included in the "Instant Online" price.

Class 4A Trade show: Parts are sanded and primer plus painted to customer color, for a fully painted and "trade show" quality finish of the exterior surfaces including texturing and painting to a custom color if needed. The projects will be quoted after review of the specifications.

Class 5A Special: Parts are polished to give a glass like look on the clear resins. These finishes are only estimated on the "Instant Online Quotes".

Notes: When competitively quoting SLA different service bureaus quote different finish levels! You can't be sure of what you are getting unless you ask.

The above list clarifies your choices here at Stereolithography.Com and gives you control over your parts and prices. Pick the finish that fits your needs. The higher the number the higher the cost of finishing. Our Class 2A can be considered the industry standard and accounts for 70% of all parts we build, Class 1A being the most economical where you the customer can opt to do the finishing.

STL (stereolithography) Files

STL (stereolithography) Files
The .STL file format has become the Rapid Prototyping industry's defacto standard data transmission format and is the format required to interact with stereolithography machines. This format approximates the surfaces of a solid model with triangles and lacks engineering data! The STL format was designed to give just the amount of data in the form of meshes to operate the Stereolithography machines but not actual engineering data. This format is very difficult to utilize for any purposes other that the 3D building we do in these machine, not good fro reverse engineering.
Almost all of today's CAD systems are capable of producing an STL file. For the user the process is often as simple as selecting File, Save As, STL. Below are steps for producing high quality STL files from a number of today's leading CAD systems. In all cases, export your STL file as a Binary file. This saves on time and file size.

(Please note, these are only general guidelines and may not work or produce the best possible STL file in some cases. Please consult you user's guide or the software's developers for more information or technical support. Should we determine that your STL file is not adequate for production we will contact you for an updated file.)

AutoCAD
Your design must be a three-dimensional solid object to output an STL file.
1. Set the FACETRES = 10
2. Use the STLOUT command to export your STL file
Alibre

1. File
2. Export
3. Save As > STL
4. Enter File Name
5. Save

I-DEAS
1. File > Export > Rapid Prototype File > OK
2. Select the Part to be Prototyped
3. Select Prototype Device > SLA500.dat > OK
4. Set absolute facet deviation to 0.000395
5. Select Binary > OK
IronCAD
1. Part Properties > Rendering
2. Set Facet Surface Smoothing to 150
3. File > Export
4. Choose .STL
Mechanical Desktop
1. Make sure you save your work before attempting this procedure.
2. Set the FACETRES = 6 (As above in AutoCAD instructions)
3. You will have to "Explode" your parametric solid to export an .stl output (Special note: DO NOT save your work after "Exploding")
4. Use the STLOUT command to export your STL file.
ProE
1. File > Export > Model
2. STL
3. Set chord height to 0. The field will be replaced by minimum acceptable value.
4. Set Angle Control to 1
5. OK
SolidDesigner
1. File > External > Save STL
2. Select Binary Mode
3. Select Part
4. Enter filename
5. Enter Max Deviation Distance of .01mm
6. Click OK
SolidEdge
1. File > Save As
2. Set Save As Type to STL
3. Options
4. Set Conversion Tolerance to 0.001in. or .0254mm.
5. Set Surface Plane Angle to 45.00o
6. Save
SolidWorks
1. Tools > Options > Export
2. STL Options
3. Set Quality to Fine
4. File > Save As
5. Set Save As Type to STL
6. Save
Unigraphics
1. File > Export > Rapid Prototyping
2. Set Output type to Binary
3. Set Triangle Tolerance to 0.0025
4. Set Adjacency Tolerance to 0.12
5. Set Auto Normal Gen to On
6. Set Normal Display to Off
7. Set Triangle Display to On

3D Solid Modeling

3D Solid Modeling

Solid Modeling is the creation of a computer-generated 3D drawing of an object, a "Digital master model". The 3D CAD file that is created is the same file that the Stereolithography machines use to build from. The file format that most SLA machines operate on is STL. Most advanced CAD programs can export this format directly. A Digital master model can be created from an existing object either through 'digitizing' and or reverse engineering.

Our in house staff can assist you with you Digital master model needs, such as 2D to 3D Drawings, Solid Model Repair and Modification, and STL model production for Stereolithography.

STL (stereolithography) Files

STL (stereolithography) Files
The .STL file format has become the Rapid Prototyping industry's defacto standard data transmission format and is the format required to interact with stereolithography machines. This format approximates the surfaces of a solid model with triangles and lacks engineering data! The STL format was designed to give just the amount of data in the form of meshes to operate the Stereolithography machines but not actual engineering data. This format is very difficult to utilize for any purposes other that the 3D building we do in these machine, not good fro reverse engineering.
Almost all of today's CAD systems are capable of producing an STL file. For the user the process is often as simple as selecting File, Save As, STL. Below are steps for producing high quality STL files from a number of today's leading CAD systems. In all cases, export your STL file as a Binary file. This saves on time and file size.

(Please note, these are only general guidelines and may not work or produce the best possible STL file in some cases. Please consult you user's guide or the software's developers for more information or technical support. Should we determine that your STL file is not adequate for production we will contact you for an updated file.)

AutoCAD
Your design must be a three-dimensional solid object to output an STL file.
1. Set the FACETRES = 10
2. Use the STLOUT command to export your STL file
Alibre

1. File
2. Export
3. Save As > STL
4. Enter File Name
5. Save

I-DEAS
1. File > Export > Rapid Prototype File > OK
2. Select the Part to be Prototyped
3. Select Prototype Device > SLA500.dat > OK
4. Set absolute facet deviation to 0.000395
5. Select Binary > OK
IronCAD
1. Part Properties > Rendering
2. Set Facet Surface Smoothing to 150
3. File > Export
4. Choose .STL
Mechanical Desktop
1. Make sure you save your work before attempting this procedure.
2. Set the FACETRES = 6 (As above in AutoCAD instructions)
3. You will have to "Explode" your parametric solid to export an .stl output (Special note: DO NOT save your work after "Exploding")
4. Use the STLOUT command to export your STL file.
ProE
1. File > Export > Model
2. STL
3. Set chord height to 0. The field will be replaced by minimum acceptable value.
4. Set Angle Control to 1
5. OK
SolidDesigner
1. File > External > Save STL
2. Select Binary Mode
3. Select Part
4. Enter filename
5. Enter Max Deviation Distance of .01mm
6. Click OK
SolidEdge
1. File > Save As
2. Set Save As Type to STL
3. Options
4. Set Conversion Tolerance to 0.001in. or .0254mm.
5. Set Surface Plane Angle to 45.00o
6. Save
SolidWorks
1. Tools > Options > Export
2. STL Options
3. Set Quality to Fine
4. File > Save As
5. Set Save As Type to STL
6. Save
Unigraphics
1. File > Export > Rapid Prototyping
2. Set Output type to Binary
3. Set Triangle Tolerance to 0.0025
4. Set Adjacency Tolerance to 0.12
5. Set Auto Normal Gen to On
6. Set Normal Display to Off
7. Set Triangle Display to On

What is Rapid Prototyping

What is Rapid Prototyping?

Rapid Prototyping or Rapid Prototype (stereolithography) is a process which produces a physical, three dimensional object, a conceptual model or master pattern. A rapid prototyping machine uses a computer controlled laser to cure a photo-sensitive resin, layer by layer, to create the 3D part. Producing a pre-production SLA of a part can greatly enhance the geometric visualization of a product, as well as communication between project team members. For photo-optic stress analysis as well as dynamic vibrational analysis, which further extends engineering design capabilities, a rapid prototyping model

What Is Stereolithography?

What Is Stereolithography?

Stereolithography (SLA) is a "Rapid Prototyping" process which produces a physical, three dimensional object , a "conceptual model" or "master pattern"!

Always produced from computer solid model, "3D CAD file", "master model".

A stereolithography machine uses a computer controlled laser to cure a photo-sensitive resin, layer by layer, to create the 3D part.

Producing a pre-production SLA prototype of a part can greatly enhance the geometric visualization of a product, as well as communication between project team members.

Stereolithography is fast, allowing prototypes to be made in a matter of days, and the complexity of the model is seldom a factor.

Benefits of Stereolithography
- Crisp, highly-detailed pieces
- Speed of delivery (usually 2-3 days)
- Tolerances within .004"/inch
Best Applications of SLA Technology
- Aesthetic & conceptual models
- Parts requiring detail & accuracy
- Master patterns for castings and secondary processes
- Medical models.
Stereolithography master models can also be used for "master patterns" when it comes time for metal castings and are easily modified to accommodate any last minute changes. Additionally, SLA models can be used for photo-optic stress analysis as well as dynamic vibrational analysis, which further extends engineering design capabilities.

SLA is really "Rapid Modeling" since the objects generated from existing photo-sensitive resins or photo polymers do not have the physical, mechanical or thermal properties typically required of end use production material. There is much ongoing research and development in the area of durable materials.

Rapid Prototyping is the next step in fast, cost effective part production. This is cutting edge technology, which can be applied to almost every industry, including oil refining, petrochemical, power, marine, and municipal and medical. Stereolithography can be a very practical and useful process in many situations.

The material of SLA the physical characteristics（Remark）

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