L e c t u re 5

Vat Photo-polymerization Processes

C o nte nt s

1. Introduction – Photo-Polymerization Process

2. Vector Scan SL
3. Mask Projection Approach
4. Materials
5. Reaction Rates in SLA
6. Printer Characteristics
7. Questions and Answers
1 . Introduction – Photo-Polymerization Processes

• Primary material: liquid, radiation curable resins (photopolymers)

• Radiation source: UV range lights
• Most photopolymer reacts with the UV lights and undergo a chemical
reaction to become solid.
• This is called as photo-polymerization.
• Start to SLA technique
• By Chuck Hull in 1980s.
• He discovered that solid polymer patterns could be produced.
• This was the beginning of stereolithography (SL) technology.
• The company 3D Systems was created shortly thereafter.
• Types of SLA techniques

1. Vector Scan or point-wise approach

• Typical of commercial SL machines.

• Laser Beam is used here.
• The need to recoat, or apply a new layer of resin.
2. Mask Projection approach

• Irradiate entire layers at one time.

• Digital Micromirror DeviceTM (DMD) to project light on required area.
• The need to recoat, or apply a new layer of resin is required.
3. Two-photon approach

• It is essentially high resolution point-by-point approach.

• Laser Beam is used here.
• Photopolymerization occurs at the intersection of two scanning laser beams.
• The part is fabricated below the resin surface, making recoating unnecessary.
2 . Vector Scan SL

• Basics
1. This process also known as Stereolithographic Apparatus (SLA)
2. It is an original 3D Printing technology – coined by Charles W. Hull
3. He founded 3D Systems company to commercialese it.

• Mirror and Laser

1. Mirror – Galvanometer/galvos (one on x-axis and Y-axis)
2. Mirror helps in scanning the laser beam across the layer
3. Laser – Solid state laser

• Part Preparation Steps:

1. CAD File / file from reverse engineering
2. STL file
3. Part preparation
4. Finally, laser scanning to build the part
5. Post Processing – cleaned, post cured, and finished
3 . Mask Projection Approach

• This process also called as digital light processing (DLP)

• DLP uses a digital light projector screen to flash a single image of each layer all at
once (or multiple flashes for larger parts)
• DLP is faster than SLA

• Digital Micromirror Device and Light

• A DMD is an array of micro-mirrors that control where light is
projected
• Light is projected onto the resin using light emitting diode (LED)
screens or a UV light source (lamp)
SLA vs DLP

SLA DLP
Light Source Point Laser Voxel Approach (due to light)
Speed Slow - tracing the cross- Fast – as an entire area is exposed
sectional area with a laser point once
Resolution 130-150 micron 1024 X 780 pixel
4 . Photo Polymerization Material

 Difference between thermoplastic and

thermosettingmolecularstructure

 Thermoplastic – remelting can be done – liner or

branched structure
 Thermosetting – remelting can not be done – cross
linked
 Thus, thermosetting shows less creep and stress
relaxation compared to thermoplastic material.
 Polymerization

• Two types:
1. Free-Radical polymerization
2. Cationic polymerization – with photoinitiator

• It is exothermic reaction, but we need a catalyst to initiate the

reaction.
• Photo-initiator acts as catalyst
 Howpolymerizationoccursduringprocess?
• Key elements required for photopolymerization – Monomer + Photoinitiators +
Oligomers (Binder)
• When hit with a light source, photoinitiators will transform light energy into
chemical energy, causing the oligomer/ binders and monomer mixture to form
three-dimensional polymer networks.

P-I = Photoinitiator
•
-I = Free radical
M = Monomer

Termination of chain
 DifferencebetweenAcrylatesandEpoxideSLresin

Acrylates SL Resin (1989-90) Epoxide Resin (1988)

1. High Reactivity 1. Slow photo speed

2. Produces weak part 2. Harder and stronger (brittle)
3. High shrinkage and curling chances 3. Less shrinkage (5-20%) and thus
in the part More accurate. Ring opening leads less
shrinkage
4. Oxygen inhibition 4. No oxygen inhibition and thus lower
photo initiator centration, lower
residual Oder
5. Additional crosslinking causes more 5. Excellent adhesion and no curling of
shrinkage and thus more stresses in the part
layer
6. Less sensitive to humidity 6. Sensitive to humidity which can
inhibit polymerization.
 Acrylates SL Resin (1989-90) Epoxide Resin (1988)

7. Free Radical polymerization 7. Cationic polymerization

8. First, photoinitiator becomes 8. first, ring opens – give site for other
reactive –-- and causes multiplication of chemical bond –
monomer --- crosslinking happens after
grows enough so that they can come
together.
9. Thus, High photospeed – but high 9. thus, minimal volume change, so less
shrinkage and tendency to warp and shrinkage and less warp and curls
curl

• Solution –
• All commercial available SL resins will have epoxides with some
acrylate content – Hybrid resins
• This gives combine advantages of both resins
 Resin Formulations

• Resin = Monomer + Oligomers + Photoinitiator + photosensitizers

• Resin suppliers create ready-to-use formulations by mixing the oligomers

and monomers with a photoinitiator, as well as other materials to affect

reaction rates and part properties.

• Photosensitizers - to shift the absorption toward longer wavelengths

5 . Reaction Rate in SLA
• It is very complex.
• Let’s look at qualitative way for the same.
• Rate of polymerization (Rp)= rate of monomer consumption

Formula 1

Where, Rp = Rate of polymerization, I = photoinitiator and M=

Monomer

• Formula shows that polymerization rate is proportional to the concentration of

monomer, but is only proportional to the square-root of initiator
concentration.

• The higher the rate of polymerization, the faster parts can be built.
• By controlling concentration of initiator, we can increase the rate.
Formula 2

Where, Vo = average molecular weight of polymer

Rp = Rate of polymerization,
Ri = rate of initiation of macromonomers
I = photoinitiator and
M = Monomer
• Equation tells that the average molecular weight of polymers is the ratio
of the rate of propagation and the rate of initiation.
• Now this equation is tell that increasing I is not always good as it reduces the
molecular weight.

(1) and (2) indicate a tradeoff between these characteristics.

• However, for epoxies, equation 2 does not apply.

6 . Printer Characteristics
A. Printer Parameters:
• Most of the parameters will be fixed
• Layer height: 25-100 micron
• For very fine feature – SLA is better than DLP.
B. Bottom-up and Top-up
• Vat Photopolyerization machines can produce part in two orientations: Bottom-Up
and Top-Up

(i) Bottom - Up

1. Light source is positioned below the surface of a resin

2. Initially, the gap between the platform and base of platform is one layer
thickness.
3. The light source (laser, UV lamp or LED screen) cures the thin layer of resin,
solidifying it.
4. A special coating stops the resin from sticking to the base of the vat.
5. Moving up one-layer thickness
(ii) Top - Down

• light source above the build platform

• The build platform begins at the very top of the resin vat with a thin layer of resin
coating it.
• The light source cures the thin layer of resin
• Once the first layer has cured, the build platform moves down 1 layer Thickness
(iii) Challenges: Bottom – UP

• For a bottom-up print to be successful, reducing the forces on the newly

printed layers during the separation stage is critical.
• The separation stage creates areas of high stress
• It can lead to part failure and warping

(iv) Challenges : Top-Down

• The platforms must also move slowly into the resin to ensure no air bubbles
are created, which have a detrimental effect on print quality.
• Build platforms are typically perforated to reduce the disruptive forces on the
platform.
C. Support Structure
• Yes, supports are required, similar to FFF.

1. Top – Down Printer –

• Support requirements are similar to FFF with overhanging features and
bridges.
• Needing material to hold them up and allow them to accurately be
printed.

2. Bottom – Up Printer –
• Support is more complicated.
• Large horizontal surfaces (build layers) can
result in large forces.
• If the peeling stage is unable to separate
the build from the vat, the print can fail.
• Parts are printed at an angle.
D. Post Processing

• Compulsory – Support removal

• Surface Finish – Sanding or wet sanding

• Aesthetic –
o Mineral oil Finish - gives glossy surface finish
o Spray painting – eliminate layer lines
o Polishing

Basic Support Wet Sanding UV Protective

acrylic lacquer Polished
Removal
E. Benefits and Limitations

• Benefits
1. Smooth surface finish and the high accuracy and detail the technology
2. Thus, it is used for producing injection molded-like prototypes, for visual
models, for high detail parts.
• Limitations

1. Photopolymers are brittle and do not have the impact strength or durability.
2. Parts printed with SLA/DLP also typically have a limited life.
3. They experience a loss of mechanical properties over time and degrade in
the presence sunlight. Coatings are applied to extend their life.
4. These material limitations are the main reason that Vat Polymerization
technologies have not been widely adopted for functional applications.
F. Common Applications

• SLA Parts are good for ==== Visual Applications, Prototyping where a smooth
surface finish and high accuracy is required 

1. Injection mold-like prototypes

• Because of its smooth surface
• This allows designers to quickly print a design to review without needing to
invest in expensive tooling.
2. Jewelry (investment casting)

• Because of its smooth surface

• This allows designers to quickly print a design to review without needing to
invest in expensive tooling.
3. Dental Applications

• Dental models, surgical guides, appliances, crowns and bridges.

• The ability to produce parts to a high level of accuracy and detail and the
number of materials available
4. Hearing Aid
• People now wearing hearing aids produced with Vat Polymerization
technologies.
• The ability to print the smooth and organic surfaces
• 97% of all hearing aids now being produced via Vat Polymerization
7 . Questions and Discussion

1. What is Photo-polymerization Method?

2. What are the types? Difference between them?
3. Material required for SLA?
4. Bottom-up vs Top-up?
5. Applications?
6. Advantages and Disadvantages?
Thank You!