Building around inserts: methods for fabricating complex devices in stereolithography

Stereolithography apparatus (SLA) is capable of in situ fabrication of complex parts, as well as mechanisms and complex devices with embedded components. In this paper, a series of example devices are presented to illustrate the power of building around embedded components (inserts). The problem formulation, solution approach, and specific rules and procedures are presented using these examples and experimental results. A case study approach is used for presentation. These procedures and results lend insight into promising new applications of SLA technology, as well as novel methods of implementing additional functionality into SLA and other rapid prototyping technologies.