A multi-axis SLA prototype apparatus

One of the most common Rapid Prototyping (RP) technologies, the stereolithography apparatus (SLA) fabricates 3-dimensional parts using a layer-based, additive fabrication processes by tracing part cross-sections on the top surface of a vat of liquid photopolymer. Up to now, usage of the SLA process has been limited to piece parts. We are interested in building fully functional prototypes containing various types of hardware while greatly increases the complexity of parts being produced. To accomplish this, we are investigating methods for building around embedded components, where these components are motors, circuit boards, bushings, etc. While it is possible to fabricate such assemblies using conventional SLA technology, we believe that much greater functionality and flexibility can be achieved if the architecture of typical SLA machines is modified to incorporate greater freedoms. In this paper we present a prototype system that shows great promise in expanding the degrees of freedom of SLA machines, thus getting one step closer to realizing the ability to build functional parts with embedded inserts. We believe that our process and results lend insight into promising new applications of SLA technology, as well as methods of implementing additional functionality into SLA and other RP technologies.