Usage of accuracy models in stereolithography process planning

Determining whether a set of tolerances on a part can be met by a rapid prototyping (RP) machine is often difficult. To achieve a set of tolerances as closely as possible, relationships between part geometry, tolerances, and process variables must be understood quantitatively. This paper presents an empirical model for stereolithography apparatus (SLA) accuracy, as specified by geometric tolerances, and a process planning method based on response surface methodology and multiobjective optimization. Response surfaces are used to capture the relationships among part surfaces, tolerances, and process variables. These response surfaces were generated by extensive design‐of‐experiment studies for a variety of geometries. An annotated STL data format is also presented that enables the inclusion of tolerance and surface information in faceted representations. Application of the accuracy models and process planning method is illustrated on one part.