Abstract In recent years, Rapid Prototyping Technology (RPT) has been implemented in many spheres of industry, particularly in the area of product development. Existing processes provide the capability to rapidly produce a tangible solid part, directly from three dimensional Computer-Aided Design (CAD) data, from a range of materials such as photocurable resin, powders and paper. In many situations, the desired end product of a developmental cycle is a metallic object that is dimensionally stable and of high accuracy, whether it is a component or a tool. However, in most cases, models built in the acrylic based resin in the StereoLithography process has not yielded the desired quality and this has led to a shift in the use of this resin to some more expensive ones that have longer build time. A unique experimental investigation has been carried out to statistically determine the optimum build parameters to be used with the use of Taguchi Method, as to improve the SLA product quality. Two new hatch styles have been developed in this study which has resulted in the overall improvement of the part surface finish.