Development of a multifunctional test bench and application in precise 3D SLA printing

Abstract

3D printing technologies have recently experienced significant growth in the public interest. This phenomenon mainly comes from the easiness and affordability that these kinds of technologies can offer nowadays. Current scientific research therefore focuses on developing printers that are cheaper, more precise, and easier to use. In this context, the Stereolithography printing technology (SLA) is rapidly evolving. The printing precision it offers indeed makes this printing technique one of the most promising technologies for the future.

In this thesis, the objective is to develop an SLA printer that challenges state-of-the-art commercial printers in terms of Z-axis precision. The printer is built on a multifunctional mechanical test bench that handles the printer's motion. This work starts by describing the SLA printing technique as well as the performances that can currently be obtained with commercial printers.

It then covers, in detail, the development of the multifunctional test bench. Such a test bench can be viewed as a precise one-dimensional motion device that includes several sensors. The device development is then followed by a complete characterization procedure. This characterization mainly focuses on finding theoretical test bench limits for SLA printing precision.

The goal of the work is to reach micrometric precisions in the printing process. To reach this objective, a precise feedback loop is then developed along with a motion controller. The theoretical properties of those different elements are also described.

The last part of the work is dedicated to the SLA printer. Its design is described and the different elements and constraints required for its working are detailed and explained. The inclusion of the printer into the test bench framework is also provided. The built printer performances are then studied, both in terms of motion and printing precisions.