Virtual-to-real 3D space conversion:

the advantages and limitations of laser stereolithography

J. Carnický Jr.* M. Zimanyi † A. Mateašik‡ And D. Chorvát Jr.
Department of nuclear physics and biophysics, Department of Computer Graphics, FMFI International Laser Centre

Introduction
Each of the methodsof rapid prototyping (RP) has its inherent advantages and also its individual
limitations [Pham and Gault, 1998]. One of the advantages of the additive process is the ability to
make holes of complicated geometry, large scale models of porous structures, or bottle like structures
with complicated interior surface. Also models with close surfaces of complicated geometry can be
made using RP. For subtractive process it is a problem to generate two spherical surfaces close to
each other, because the drill can not go enough deep without colliding one of the surfaces, but using
RP technologies, there is a possibility to generate such model. Also sharp interior edges can be made
by RP.
Laser stereolithography, or 3-dimensional printing, was developed in 1987 as the first commercially
available layer-additive process to enable the generation of objects directly from a CAD data. The
stereolithography apparatus builds a model from solid layers created by hardening a liquid
photosensitive resin by curing with ultraviolet laser.
Optimization of the process parameters in stereolithography is the fundamental problem of
generating appropriate prototypes from 3D data.
The model of the part with supports is exported using Magics RP in the bitmap files of each layer our
stereolithograph uses the SLI (slice) file format. During this conversion the model is sliced into the
equidistantly spaced layers, with the offset corresponding to the layer thickness parameter. The
sequence of these two layer types as well as the type of hatching are determined during conversion of
STL to SLI data formats. The speed and accuracy of the RP process as well as the model surface
properties are strongly affected by the method how each layer is build [McClurkin, 1998]. In our
technology we use the StarWAWE and ACES build styles [Pham and Gault, 1998].
In the final step the SLI files are used as an input to the stereolithography machine. Software SliTgf
generating files necessary for driving the stereolithograph technology during the whole part
manufacturing and the software LsOiII controlling the laser stereolithograph are used for creation of
the model from the liquid resin. After the exposition to the UV laser light, the epoxy resin containing
monomers is solidified (polymerized). The speed of the laser movement (and/or the laser power) has to
be set to the value appropriate for the chosen layer thickness.

If the speed of laser is too high, the layers are not enough connected and the mechanical properties
Technology of the part are poor. If the movement is too slow, the first layer is thicker, likewise all other layers that are
not fully supported by previous layers. On the other hand, some level of over-curing is necessary for
The models in additive RP process are created in a following sequence of 5 steps:
bonding the subsequent layers together, so it is necessary to find and use the optimal laser settings. To
1 Generation of a 3D (CAD) model avoid the increased thickness of the very first layer, one can adjust the Z-compensation in Magics RP
2 Converting of the CAD model into the STL format software. The Z-compensation makes the virtual model smaller on its bottom surface. After the Z-
3 Slicing the STL file compensation, the real model often fits better the original (virtual) model dimensions. During
4 Building the model by adding the layers polymerization the resin shrinks in volume by ~68 % [Lu et al, 1995]. Due to this effect, a residual stresses
5 Post processing and/or distortion of the parts in the Z direction are present in the created models. We have evaluated
the geometric distortions and
mechanical properties of some of
our models build from the IPLIT1 resin.
In large models and not-optimal
parameter settings the distortions
reached up to 3.7 %

Figure 3. Results
Small models made by the Cibatool SL 5170 In our laboratory we had former
resin. The underlying paper has a 1 mm grid. experience with layer thickness
0.3mm / 0.25 mm using the IPLIT1
epoxy resin. In 2005 a Cibatool SL
5170 resin was installed in the LS-250
machine, capable of building
models with the layer thickness
0.100-0.125 mm.

The overall accuracy (compared to

the original virtual object) of the small
models created with 0.1mm layer
thickness (Fig.3) was found to be
Figure 1. Scheme of the laser stereolithography apparatus. ~0.15 mm. For bigger models the
accuracy depends on many
parameters. An example of the
For stereolithography, the precision depends mostly on the photopolymer used, due to the inherent model generated using 0.1 mm
physical limitations of the photopolymerisation process (the precision of recent opto-mechanical layer thickness is shown at Fig.4,
components is by order of magnitude higher). depicting the St. Martin cathedral in
Bratislava, scanned using stereo-
The model is build upon a platform, that moves along the Z axis with high precision (Fig.1). The laser photogrammetry by one of the co-
focus is moved on the surface of the liquid resin (in the XY plane) using two computer-controlled authors (M. Zimanyi) within the frames
mirrors. The laser stereolithograph LS 250 (NICTL, Shatura) installed at the International Laser Centre in of the project of Virtual Bratislava.
Bratislava is shown at Fig.2.
Figure 4. Model of the St .Martin
It allows to create models with cathedral (83.2x43.2x92 mm).
dimensions up to 250x250x250 mm.
The laser focus has 0.250 mm in
diameter, its movement in XY plane
is calibrated with accuracy better
than 0.01 mm.
During scanning, the midpoint of the
Conclusion
laser moves 0.125 mm inside the
model layer. The platform elevator In our contribution we have tried to summarize the most important
has the accuracy of 0.01 mm, but
there are no commercial resins parameters guiding the process of preparation and creation of
available for such thin layers. the physical replicas from the virtual 3D models by laser
The overall precision of the system is stereolitography. At present, the physical models (replicas) with
0.1 mm, but it strongly depends on the dimensions up to several tens of centimeters and sub-
the resin and system parameters
used.
milimeter accuracy can be produced in our laboratory from the
Figure 2. Stereolithography chamber
virtual 3D data.
The first step of preparation of the 3D
models used as an input for stereolithography is their conversion to the STL file. In our laboratory this is
achieved using Magics RP software (Materialise, Belgium). The model is also checked for errors like References
inverted triangles, sharp edges, crossing triangles, holes etc. When the model is fixed, it is positioned on
the virtual platform and the supports are generated using Magics RP.
LU, L., FUH, J.Y.H., NEE, A.Y.C., KANG, E.T., MIYAZAWA, T., CHEAH, C.M. 1995. Origin of schrinkage,
distortion and fracture of photopolymerized material, Materials Research Bulletin, vol. 30, 12,
Optimizing the part orientation is necessary also to minimize the stair-stepping error of the surface.
1561-1569.
Further, the real replica of the model is created by physical adding of the layers from selected
material.
MCCLURKIN, J., ROSEN, D.W. 1998. Computer-aided build style decision support for
stereolithography, vol. 4, 1, 4-13.
There are two critical requirements for support generation:
1. The support should hold the model in proper position during the whole process with the PHAM, D.T., GAULT, R.S. 1998. A comparison of rapid prototyping technologies, International
accuracy of the modelled object. Journal of Machine tools & Manufacture, vol. 38, 1257-1287.
2. The supports should be as thin as possible, as they need to be removed after model building.