Recent advances in the development of stereolithography-based additive manufacturing processes: A review of applications and challenges

Additive manufacturing processes have progressed over recent years due to their superiority over conventional manufacturing methods. Their ability to fabricate materials with complex structures, increased precision, and reduced cost have opened avenues for various industrial applications, including biomedical, electrical, mechanical, aviation, and filtration, and led to their development over time. Stereolithography (SLA) is an additive manufacturing technique, through photopolymerization reaction, it solidifies a selective resin to produce three-dimensional objects. SLA has emerged as a leading 3D printing technique, revolutionizing prototyping and production across various industries. SLA has been through four generations of development and advancement, resulting in its improved performance, the diversity of materials, and the variety of applications. Stereolithography has diversified its material and emerged as a promising method for polymer-based composite when operating under optimized conditions. SLA offers superior resolution, high finish quality, improved speed and precision, and is cost-effective compared to alternative techniques like Fused Deposition Modeling (FDM). This current study aims to comprehensively review SLA development, its processes, applications and inherent challenges in mechanical, electrical and biomedical fields.