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<p>The growing requirement for lightweight and high-strength components in aerospace, automotive, and biomedical fields has encouraged the advancement of modern manufacturing technologies. Additive manufacturing (AM), particularly stereolithography (SLA), has become a leading method because it offers outstanding dimensional accuracy, fine surface quality, and the freedom to fabricate geometrically challenging parts. Lightweight bolts play a significant role in engineering systems where weight reduction leads to improved performance, fuel efficiency, and overall system reliability. Epoxy resin, known for its low density and favorable mechanical characteristics, is a promising candidate for such structural components. Since machining epoxy in molten form is difficult and can affect final quality, SLA presents an efficient solution for producing bolts without additional processing challenges. SLA-fabricated bolts provide advantages such as design flexibility, material savings, rapid manufacturing capability, improved strength-to-weight ratio, ease of customization, and reduced overall assembly mass. These merits demonstrate the suitability of SLA for creating structural fasteners intended for conditions requiring moderate strength and lightweight characteristics. The present study focuses on the efficient fabrication of epoxy bolts through SLA and offers useful insights for future developments. In SLA, mechanical properties largely depend on processing parameters; therefore, optimization was carried out using response surface methodology (RSM). Thirty-one experimental trials were executed using clear epoxy resin with five selected parameter levels. Results revealed that a layer thickness of 5&#xa0;µm provided the highest improvement in compressive strength, reaching a 23.61% increase. Similarly, a rising height of 5&#xa0;mm improved compressive behavior by 20.05%. Moreover, an exposure time of 8&#xa0;s and a bottom exposure layer of 9&#xa0;mm contributed enhancements of 16.21% and 11.71%, respectively. Under the optimized printing conditions, the printed bolt successfully withstood an average compressive load of 4.003&#xa0;kN, confirming its viability for lightweight engineering applications.</p>

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Statistical and Experimental Study of Lightweight 3D-Printed Bolts Using Stereolithography Process

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • Nitesh Kumar Malviya,
  • Vishal Gupta,
  • Vivek Jain

摘要

The growing requirement for lightweight and high-strength components in aerospace, automotive, and biomedical fields has encouraged the advancement of modern manufacturing technologies. Additive manufacturing (AM), particularly stereolithography (SLA), has become a leading method because it offers outstanding dimensional accuracy, fine surface quality, and the freedom to fabricate geometrically challenging parts. Lightweight bolts play a significant role in engineering systems where weight reduction leads to improved performance, fuel efficiency, and overall system reliability. Epoxy resin, known for its low density and favorable mechanical characteristics, is a promising candidate for such structural components. Since machining epoxy in molten form is difficult and can affect final quality, SLA presents an efficient solution for producing bolts without additional processing challenges. SLA-fabricated bolts provide advantages such as design flexibility, material savings, rapid manufacturing capability, improved strength-to-weight ratio, ease of customization, and reduced overall assembly mass. These merits demonstrate the suitability of SLA for creating structural fasteners intended for conditions requiring moderate strength and lightweight characteristics. The present study focuses on the efficient fabrication of epoxy bolts through SLA and offers useful insights for future developments. In SLA, mechanical properties largely depend on processing parameters; therefore, optimization was carried out using response surface methodology (RSM). Thirty-one experimental trials were executed using clear epoxy resin with five selected parameter levels. Results revealed that a layer thickness of 5 µm provided the highest improvement in compressive strength, reaching a 23.61% increase. Similarly, a rising height of 5 mm improved compressive behavior by 20.05%. Moreover, an exposure time of 8 s and a bottom exposure layer of 9 mm contributed enhancements of 16.21% and 11.71%, respectively. Under the optimized printing conditions, the printed bolt successfully withstood an average compressive load of 4.003 kN, confirming its viability for lightweight engineering applications.