Research on the large-format splicing method for stamping-type digital light processing 3D printing

Abstract In response to the strong demand for the development of large-format digital light processing (DLP) 3D printing technology, the use of multiple ultraviolet (UV) fixed splicing poses challenges such as high costs and limitations in print size. Therefore, this paper proposes a stamping-type DLP surface splicing 3D printing method, namely, achieving the large-format DLP 3D printing effect through the intermittent movement of a single UV machine along two axial directions. To address the splicing issues inherent in the stamping-type DLP 3D printing surface printing method, we have divided the splicing areas and deduced the principles governing energy distribution at the seams of adjacent printed areas. By introducing a normal distribution process and combining it with the projection function and energy distribution principles, a method for the gradient energy distribution of overlapping splicing zones is proposed. The effectiveness of this method is experimentally validated, demonstrating that the minimum size error of printed pieces is -0.0591, the minimum error in surface roughness at splicing and non-splicing areas is 0.13%, the tensile strength is comparable to that of integral curing, and the overall hardness distribution is relatively uniform.