Multi-Material Stereolithography (MSLA)

Summary
Date	2022-?
Keywords	3d-printing, SLA, MSLA, multi-material, photopolymer, additive manufacturing
Partners	Prof. David St-Onge

Stereolithography (SLA) and masked SLA (MSLA) are powerful photopolymer additive manufacturing techniques known for their high resolution and smooth surface finish. However, commercially available systems are almost exclusively single-resin: one material per print. This limits the ability to produce graded structures, multi-functional parts, or integrated flexible-rigid assemblies in a single build.

This project develops a novel multi-resin MSLA printer with a custom automated wiper mechanism that enables layer-by-layer switching between different photopolymer resins. The system is designed to enable functional gradients (stiffness, conductivity, optical properties) within a single printed part, opening new possibilities for integrated structural and functional components.

Research published in 2025 demonstrates the design, fabrication, and validation of this multi-material MSLA system, with initial demonstrations on micro-lattice structures combining different photopolymer formulations within the same architecture.