Strategy for minimizing deformation of DLP 3D printed parts using sub-build plate

Three-dimensional (3D) printing is gaining significant attention as an innovative manufacturing method in various industries. In particular, 3D printed parts produced using digital light processing (DLP) have attracted considerable interest because of their rapid production and high precision. However, during the manufacturing process, the manufactured parts can experience deformation owing to accumulated residual stress and uncured resin. We analyzed part deformation during additive manufacturing and post-processing through experiments. Based on the analysis results, we propose the introduction of a sub-build plate to achieve effective manufacturing and post-processing. The sub-build plate constrains the parts, thereby enabling post-processing such as cleaning, drying, and UV post-curing to be performed more efficiently. The experimental results show that the suppression of additional deformation during UV post-curing in the parts constrained on the sub-build plate resulted in approximately a 2 % deformation. This is more than a two-fold reduction compared with the average deformation of 5.79 % observed in parts manufactured using conventional methods. These results demonstrate that the adoption of a sub-build plate can minimize part deformation, extend part lifespan, and reduce costs. These findings hold promise for the application of DLP printing technology in various industries and contribute to the development of new manufacturing processes.