Experimental evaluation of build orientation effects on the microstructure, thermal, mechanical, and shape memory properties of SLA 3D-printed epoxy resin

Additive manufacturing (AM) methods, popularly known as 3D printing technologies, particularly the pioneering laser stereolithography (SLA), have revolutionized the production of complex polymeric components. However, challenges such as anisotropy, resulting from the layer-by-layer construction method, can affect the thermomechanical properties and dimensional stability of 3D-printed objects. Although anisotropy in SLA 3D printing is often overlooked due to the high precision of this technique, its impact on the properties and structural performance of the 3D-printed prototype becomes more significant when printing small devices designed for precise micro-mechanisms. This experimental study investigates the impact of the chosen printing surface – a less explored factor – on the performance of SLA 4D-printed thermo-responsive shape memory epoxy (SMEp) specimens. Two identical dog-bone specimens were printed from two distinct surfaces: edge and flat surface, to examine how variations in surface area and quantity of layers influence the microstructure, thermal behavior, mechanical properties, and shape memory performance. The results of this experimental investigation reveal that specimens printed from the edge, with a higher number of layers and smaller surface area, exhibit superior interlayer bonding, tensile strength, dimensional stability, and shape recovery efficiency compared to those printed from the flat surface. Conversely, specimens with fewer, larger layers demonstrated greater elongation and thermal expansion but reduced structural integrity and shape recovery performance. These results highlight the importance of experimentally investigating how different build orientations affect the properties and performance of SLA 3D-printed materials, especially before designing and employing them in applications demanding high precision and reliability.