Novel stereolithography system for small size objects

Purpose - To satisfy the demands for rapid prototyped small-size objects with intricate microstructures, a high-resolution stereolithography (SL) system is developed. Design/methodology/approach - This 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- 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. Findings - With 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/implications - The building area limited to 65 × 65 mm, is smaller than that of current SL system. Practical implications - Small objects with intricate microstructures can be fabricated with the SL system. Originality/value - The 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.