Meniscus process optimization for smooth surface fabrication in Stereolithography

In the layer-based additive manufacturing processes, it is well known that the surface finish is usually poor due to the stair-stepping effect. In our previous study, it was shown that the meniscus approach can be used in the Stereolithography process to achieve much better surface finish. A related challenge is how to optimize parameters such that the formed meniscuses can lead to high surface finish and accurate shape. In this paper, a systematic process planning method is presented for the Stereolithography process that is integrated with the meniscus approach. Process planning, parameters characterization and meniscus parameters optimization are presented with experimental verifications. To demonstrate the systematic process, surface profile simulation, meniscus database construction, meniscus forming parameter optimization, and shape accuracy prediction have been performed using a test case based on convex surfaces. A comparison between the experimental results with and without the process planning method is presented, illustrating the effectiveness of the developed meniscus optimization method in simultaneously controlling the shape and surface finish of fabricated objects. Subsequently the simulation results are also verified with experimental results.