Investigation of Dimensional Accuracy in Stereolithography (SLA) 3D Printing: Impact of Layer Thickness, Exposure Time, Print Orientation and Curing Time

Additive Manufacturing (AM) is growing much faster because of its capability to produce complex geometries accurately without material wastage, using a CAD 3D model. It has immense scope in sectors such as aerospace, healthcare, filtration, mechanical, and electrical industries. Out of the many AM technologies available, Stereolithography (SLA) is one process that can build prototypes and end-use products using resins. SLA is particularly known for producing smooth surfaces with tight dimensional tolerances. Several SLA process parameters play a crucial role in producing dimensionally accurate parts. This study focuses on the impact of layer thickness, exposure time, print orientation, and curing time on the dimensional accuracy of SLA-printed parts. A Taguchi-based array was used to design and conduct the experimental work, and the analysis was carried out using Analysis of Means (AOM) plots and regression equations. The optimal settings improved precision, with a 0° orientation yielding the best results for the inside diameter, and 45° and 90° orientations performing best for outside dimensions. Proper curing time was also found to prevent dimensional errors. A validated prediction model showed minimal errors, thereby enhancing the accuracy of SLA-printed parts. These findings show that by optimizing layer thickness, exposure time, print orientation, and curing time, SLA printing can consistently achieve high dimensional accuracy. Such improvements make SLA more viable for industrial applications requiring precision, such as aerospace components, custom medical devices, and high-performance mechanical parts