
Accelerating Residual Stress Simulation in Stereolithography via the Laplace Transform Finite Element Method
Please login to view abstract download link
Stereolithography (SLA) is a widely used additive manufacturing technique known for its ability to produce parts with high dimensional accuracy and excellent surface finish. However, residual stresses induced during the printing process can compromise mechanical performance and are challenging to predict efficiently. Classical simulation approaches, such as time-stepping Finite Element Methods (FEM), can model the process accurately but are computationally expensive due to the need to iterate over fine time increments [1]. In this study, we introduce an alternative simulation framework based on the Laplace Transform Finite Element Method (LTFEM) combined with a fast Numerical Inverse Laplace Transform (NILT). By reformulating the governing equations in the frequency domain, our approach avoids the time-stepping loop entirely and enables the direct computation of stress fields at any desired simulation time. This transformation allows for significant parallelization and computational speed-up [2]. The framework captures the complex Free-Radical-Photopolymerization (FRP) kinetics occurring after UV exposure, incorporating a reaction model simplified using the Quasi-Steady-State Assumption (QSSA). We also present the frequency domain formulation of the laser illumination, which follows arbitrary G-code-defined scan paths, allowing realistic process simulation. Benchmark comparisons of the Laplace Transform Finite Element solver with traditional FEM simulations demonstrate that LTFEM achieves over 1200 times speed-up while maintaining or exceeding the accuracy of time-integration-based methods, especially for long simulation durations. These results highlight the potential of LTFEM as a powerful tool for accelerating SLA process simulations and improving the design and optimization of printed components. REFERENCES [1] S. Westbeek, J. A. W. Van Dommelen, J. J. C. Remmers, M. G. D. Geers, Multiphysical modeling of the photopolymerization process for additive manufacturing of ceramics, European Journal of Mechanics-A/Solids 71 (2018) 210–223 [2] T. Bakhos, A. K. Saibaba, P. K. Kitanidis, A fast algorithm for parabolic pde-based inverse problems based on Laplace transforms and flexible Krylov solvers, Journal of computational Physics 299 (2015) 940–954