SYMBIOSIS INSTITUTE OF TECHNOLOGY

Flexi Credit Course: ADDITIVE MANUFACTURING

VAT Photopolymerization

NAME PRN BATCH

Dubey Dhanraj Shevendrakumar 20070125041 Mechanical A2

Abhishek Sharma 20070125051 Mechanical A3

 INTRODUCTION
Vat Photopolymerization is an additive
manufacturing 3D printing technology. It
works by exposing a vat of liquid
photopolymer resin to light, which hardens.
The light source is often a UV laser that tracks
the object's design layer by layer. When the
laser touches the resin, it hardens and adheres
to the preceding layer, gradually completing
the sculpture. This method is known as "Vat
Polymerization," since the item is constructed
Fig : Image depicting VAT
inside a vat or container of resin. The finished PHOTOPOLYMERIZATION
product is a 3D sculpture constructed of
solidified resin with exceptional precision and
detail.
 DIAGRAM
AND
PARTS

REF: https://www.lboro.ac.uk/media/wwwlboroacuk/external/content/research/amrg/powderbedfusion%20-%20process.jpg
TECHNOLOGY USED
Vat Photopolymerization is a technology that uses a combination of light, usually
ultraviolet (UV) light, and a photoreactive resin. However the technology used in
here is STEREOLITHOGRAPHY. The resin is contained in a vat or container and is
selectively solidified by the UV light to build up the 3D object layer by layer. The light
source, which can be a UV laser, is guided by a computer-controlled system to trace
the design of the object and solidify the resin in specific areas.

Fig : Visuals of UV Light Fig : Example of Photoreactive resin

 MATERIALS USED
In Vat Photopolymerization, photoreactive resins are used as the main material. These
resins are typically liquid and can be solidified by exposure to UV light. Some common
materials used in Vat Photopolymerization include:

1) Acrylate resins: This type of resin is widely used due to its good accuracy and high
resolution.
2) Epoxy resins: These resins offer high mechanical strength and heat resistance.
3) Polyurethane resins: These resins are known for their flexibility and toughness.
4) Photosensitive silicone resins: These resins are used for making flexible and soft
parts.

NOTE: It's vital to remember that different resins have varied qualities, such as viscosity, curing time, and
UV light resistance. The resin used is determined by the application's unique needs.
 PROCESSING PARAMETERS​

PARAMETER DESCRIPTION
UV light intensity This determines the curing speed and quality of the resin. High intensity light results in faster curing,
but may also cause excessive heat buildup and induce unwanted thermal effects.

Layer thickness This refers to the height of each solidified layer of resin and has a direct impact on the final
resolution and surface finish of the object. Thicker layers result in lower resolution and coarser
surface finish, while thinner layers provide higher resolution and smoother surface finish.
Scanning speed This determines how fast the laser scans the resin and affects the curing speed and material
utilization efficiency. Faster scanning speeds can result in faster processing times, but may also cause
lower quality and increased material waste.
Wavelength of light Different resins may respond differently to different wavelengths of light. The choice of wavelength
can influence the curing speed, resolution, and strength of the final object.

Exposure time This refers to the amount of time the resin is exposed to the UV light and affects the curing depth and
quality of the resin. Longer exposure times result in deeper curing, but also increase the risk of
unwanted thermal effects.
Resin temperature This can affect the viscosity and curing properties of the resin. High temperatures can result in faster
curing, but may also cause excessive heat buildup and affect the mechanical properties of the final
object.
 SPEED AND SURFACE FINISH​​

• The surface finish of the products produced via vat photopolymerization depends on
several factors, including the layer thickness, scanning speed, exposure time, and post-
processing methods.
• In general, a thinner layer thickness and slower scanning speed result in a smoother
surface finish, while a thicker layer thickness and faster scanning speed result in a
coarser surface finish. The exposure time also affects the surface finish, as longer
exposure times can result in deeper curing and smoother surfaces, while shorter
exposure times can cause rough or uneven surfaces.
 SPEED AND SURFACE FINISH​​
• The speed of vat photopolymerization can be relatively slow compared to other 3D
printing technologies, but it offers high resolution and detail, as well as a wide range
of material options.
• The speed of vat photopolymerization depends on several factors, including the UV
light intensity, scanning speed, layer thickness, exposure time, and resin properties.
In general, faster curing speeds can be achieved with higher UV light intensity,
faster scanning speed, and thinner layer thickness.

Rough estimate: Some high-end

VAT photopolymerization printers
can print at speeds of up to several
inches per hour, which translates
to around 20-30 millimeters per
hour. (REF)​
 MECHANICAL PROPERTIES​​
• In general, the mechanical properties of Vat Photopolymerization products can be
similar or better than those of conventionally manufactured parts made of the same
material. For example, the mechanical strength, stiffness, and toughness of Vat
Photopolymerization parts made of acrylate, epoxy, or polyurethane resins can be
comparable or superior to those of conventionally manufactured parts made of the
same materials.
• The type of resin used can have a significant impact on the mechanical properties of
the final object. For example, epoxy resins are known for their high mechanical
strength and heat resistance, while polyurethane resins are known for their flexibility
and toughness.

HEAT
STIFFNESS STRENGTH TOUGHNESS FLEXIBILITY
RESISTANCE
 POST-PROCESSING

POST-PROCESSING DESCRIPTION
METHODS
Support removal The support structures used during the printing process to hold the object in place
need to be removed after printing. This can be done manually or with specialized
support removal tools.
Sanding and polishing Sanding and polishing can be used to smooth the surface of the final object, remove
surface defects, and improve the overall surface quality.

Vapor smoothing Vapor smoothing is a post-processing method that involves exposing the object to a
solvent vapor to dissolve the surface layer and create a smooth surface finish.

Painting and coating Painting and coating can be used to add color, texture, or other properties to the
surface of the final object.

Heat treatment Heat treatment can be used to improve the mechanical properties of the final object,
such as increasing the toughness, hardness, or elastic modulus.
 EFFECTIVENESS

Some of the key advantages of Vat Photopolymerization include:

1)Complex geometries: Vat Photopolymerization can produce objects with complex
geometries that would be difficult or impossible to produce with traditional
manufacturing methods.

2)High precision: Vat Photopolymerization can produce objects with high precision,
with features and details that can be as small as a few micrometers.

3)Automation potential: Vat Photopolymerization has the potential for automation,

which can lead to higher production rates, improved consistency, and reduced costs.

4)Material recycling: Vat Photopolymerization has the potential for material recycling,
which can reduce waste and improve sustainability.
 ENVIORMENTAL CONCERNS

1. Waste generation: Vat Photopolymerization can

generate waste, such as unused resin and support
structures, that can contribute to landfills and
pollution.
2. Chemicals and pollutants: Some resins used in
Vat Photopolymerization contain harmful
chemicals and pollutants, such as monomers and
oligomers, that can pose environmental risks if
not properly disposed of.
3. Energy consumption: The UV light sources
used in Vat Photopolymerization can consume
large amounts of energy, which can contribute to
greenhouse gas emissions and climate change.
4. Health and safety: Some resins used in Vat
Photopolymerization can emit hazardous fumes,
dust, and particles that can pose health and
safety risks to workers and the environment.
 LIMITATIONS

LIMITATION DESCRIPTION
Materials limitations The range of materials that can be used in Vat Photopolymerization is currently
limited, with a focus on photopolymer resins. This limits the ability to produce
objects with specific mechanical, thermal, or electrical properties.
Build size limitations The build size of Vat Photopolymerization objects is currently limited, and larger
objects can take significantly longer to produce and require more support
structures.
Layer thickness The layer thickness of Vat Photopolymerization objects is currently limited, and
limitations thinner layers can result in better surface quality and mechanical properties, but
also longer printing times.
Post-processing The post-processing methods used in Vat Photopolymerization can impact the
limitations final object's mechanical properties and surface

Cost limitations The cost of Vat Photopolymerization equipment and materials can be relatively
high, and the technology is not yet widely available for low-volume or hobbyist
applications.
NAME​ PRN​ BATCH​

Dubey Dhanraj Shevendrakumar​ 20070125041​ Mechanical A2​

Abhishek Sharma​ 20070125051​ Mechanical A3​

REFERENCES:

REFERENCE 1
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REFERENCE 5