Optimization of part orientation and adapted supports for manufacturing of ceramic parts by stereolithography using finite element simulations

TLDR: In this article, a finite element simulation of scraping is performed to analyze the best green part orientation and adapted supports during the stereolithography process, and a specific and original experiment is developed to identify the scrapings loads, essential as input data for the simulation.

Abstract: The manufacturing of ceramic green parts using the stereolithography process requires several steps, which can each influence the mechanical properties of the printed parts: dimensional precision, surface roughness and mechanical strength. The part orientation with respect to the working plan and adapted supports are key points to avoid the failure of the green part during its construction. Indeed, mechanical forces generated during the spreading of thin layers of ceramic suspension generate significant loads on the green part being printed and may displace it or lead to its rupture. It is then crucial to choose a part orientation that minimize these effects and to create adapted supports that can hold the scraping loads. In this respect, a finite element simulation of scraping is performed to analyze the best green part orientation and adapted supports during the stereolithography process. A specific and original experiment is developed to identify the scrapings loads, essential as input data for the simulation. Modellings confirms that the orientation of the support greatly influences the deformations of the green part and highlights the importance of the support stiffness that absorb the scraping forces.