The Stereolithography (SLA) technique is one of the most
prominent and widely used 3D printing technologies, extensively applied
across various industries, including construction (Jacobs, 1992). First
developed by Hull (1986) and later commercialised by 3D Systems Inc., SLA
involves selectively polymerising liquid photosensitive resin with UV light to
create high-precision parts. This technology is known for its capability to fabricate
components with high surface quality and fine resolutions down to the
micrometre scale (Wu et al., 2016). As the most common resin-based 3D
printing method, SLA is widely utilised due to its ability to produce highly
accurate, isotropic, and waterproof prototypes and end-use parts
(3DEXPERIENCE Make, n.d.). Professional SLA 3D printers, such as Formlabs’ Form
4, can print walls as thin as 0.2mm, with embossed and engraved details as fine
as 0.1mm and 0.15mm, respectively (Formlabs, 2024a).
SLA 3D printing technology has significant potential to
revolutionise the construction industry by enhancing efficiency, improving
accuracy, and enabling mass customisation. Its primary advantages include
faster production cycles, superior precision, and the ability to create
customised designs at scale. These benefits not only address existing
challenges in the construction sector, such as project delays and
miscommunication but also pave the way for smarter, more sustainable
building methods.
One of the most compelling advantages of SLA 3D
printing in the construction sector is its ability to reduce project
timelines. Construction projects often experience delays due to
prolonged design and approval processes, material shortages, and inefficient
workflows (Assaf & Al-Hejji, 2006). Traditional manufacturing methods
require multiple steps—design → prototyping → mold machining → testing—which
typically takes 4–8 weeks. In contrast, SLA 3D printing allows direct
production from digital models, reducing the lead time to just 1–2 weeks
(Singh & Singh, 2018).
Moreover, communication challenges frequently lead to
misinterpretations of design changes, especially when relying on 2D
drawings. SLA 3D printing enables architects and engineers to create highly
detailed physical models, facilitating clearer communication and reducing
misunderstandings in project planning (Formlabs, 2024a). For instance, Renzo
Piano’s company, RPBW, leveraged SLA 3D printing to produce an architectural
model in under 24 hours (Formlabs, 2024a). The latest Formlabs SLA
printer, Form 4, can print models in as little as two hours, further
enhancing project efficiency (Formlabs, 2024b).
Another key reason for advocating SLA 3D printing in
construction is its unparalleled precision and accuracy. SLA parts
have tolerances of less than 0.05mm, ensuring smooth edges and reducing
defects commonly associated with traditional manufacturing methods (3D Systems,
2023). This high level of accuracy is particularly advantageous in
applications requiring complex geometries, intricate detailing, and precise
fitment, such as structural connectors and facade elements.
The superior resolution of SLA printing reduces the
need for extensive post-processing, saving both time and resources.
In traditional manufacturing, minor errors in measurements can lead to significant
material wastage and cost overruns. With SLA, engineers can minimise
errors early in the design phase, improving final product quality and
optimising resource use.Beyond speed and accuracy, SLA 3D printing
enables mass customisation, allowing construction firms to create
bespoke components without additional costs. Unlike conventional
production, where customised designs typically require expensive and
time-consuming mold modifications, SLA printing offers flexibility in
design iteration, making it ideal for customised building facades,
interior elements, and modular construction components (Wu et al., 2016).
The concept of mass customisation has long been a goal in
construction, as it allows architects to tailor designs to individual
client needs without sacrificing efficiency. With SLA technology,
construction firms can manufacture custom parts on demand, reducing excess
inventory and lowering material waste.
Despite its numerous benefits, SLA is not the only 3D
printing method used in construction. Fused Deposition Modelling (FDM)
and Selective Laser Sintering (SLS) also offer advantages depending on cost,
print time, accuracy, and material selection.
- SLS
is more suitable for complex structural components, as SLS-printed
parts exhibit superior mechanical properties compared to SLA
(Formlabs, 2024a).
- FDM
has broader material compatibility (e.g., HIPS, PP, TPE, nylon, PLA,
ABS) and lower material costs ($80–$210 per litre), making it a
more budget-friendly option (Wu et al., 2016).
- SLA
materials, based on photosensitive resins, degrade over time when exposed
to UV light, leading to yellowing, brittleness, and reduced
performance, making them less durable than FDM materials
(Xometry, 2023).
Therefore, choosing the appropriate 3D printing
technology depends on project-specific requirements such as structural
strength, durability, and budget constraints.
SLA 3D printing is poised to transform the construction
industry by addressing critical challenges such as prolonged project
timelines, miscommunication, and the need for customisation. Its speed,
precision, and ability to facilitate mass customisation make it a valuable tool
for architects, engineers, and builders. However, its limitations,
particularly regarding material durability and cost, suggest that SLA should be
used strategically alongside other 3D printing technologies like FDM and SLS.
With ongoing advancements in hardware, software, and
materials science, SLA 3D printing is expected to drive innovation in
sustainable construction practices, including reducing CO₂ emissions
through material efficiency (UNEP, 2022). While its widespread adoption
is still in an exploratory phase, continued research and technological
breakthroughs could further enhance its capabilities, paving the way for
a smarter, more sustainable construction industry.
References
3D Systems. (2023). Stereolithography (SLA) 3D printing technology. 3D Systems. https://www.3dsystems.com/stereolithography
3DEXPERIENCE Make. (n.d.). SLA stereolithography 3D printing services. 3DEXPERIENCE Make. https://www.3ds.com/make/service/3d-printing-service/sla-stereolithography
Assaf, S. A., & Al-Hejji, S. (2006). Causes of delay in large construction projects. International Journal of Project Management, 24(4), 349–357. https://doi.org/10.1016/j.ijproman.2005.11.010
Formlabs. (2024a). 3D printing architectural models. Formlabs. https://formlabs.com/asia/blog/3d-printing-architectural-models/
Formlabs. (2024b). The ultimate guide to stereolithography (SLA) 3D printing. Formlabs. https://formlabs.com/asia/blog/ultimate-guide-to-stereolithography-sla-3d-printing/
Hull, C. W. (1986). Apparatus for production of three-dimensional objects by stereolithography (U.S. Patent No. 4,575,330). U.S. Patent and Trademark Office. https://patents.google.com/patent/US4575330/en
Jacobs, P. F. (1992). Rapid prototyping & manufacturing: Fundamentals of stereolithography. Society of Manufacturing Engineers.
Singh, R., & Singh, S. (2018). Time and cost comparison between rapid casting and conventional sand casting. Journal of Manufacturing Processes, 34, 307–315. https://doi.org/10.1016/j.jmapro.2018.04.017
United Nations Environment Programme. (2022). 2022 global status report for buildings and construction. https://www.unep.org/resources/publication/2022-global-status-report-buildings-and-construction
Wu, P., Wang, J., & Wang, X. (2016). A critical review of the use of 3D printing in the construction industry. Automation in Construction, 68, 21–31. https://doi.org/10.1016/j.autcon.2016.04.005
Xometry. (2023, December 4). 3D printing: SLA vs. FDM. Xometry. https://xometry.pro/en-eu/articles/3d-printing-sla-vs-fdm/
Edited by 02/04/2025 (Base on prof brad comment, i edited the reference list)