Optimizing Support Structures and Build Orientation in Masked Stereolithography for Dental Bridges using Taguchi-Based Design and MAIRCA

This paper addresses the critical challenge of optimizing support structures and build orientation in additive manufacturing, with a focus on the fabrication of dental bridges using the Masked stereolithography (MSLA) process. The aim of this study is to minimize the support structures and optimize the building orientation. A simulation-based analysis combined with a decision-based optimization approach was implemented to evaluate the system-generated versus user-defined support structures. The simulation analysis enabled a detailed assessment of different build orientations that may affect the number of support structures and their locations. The findings indicate that the build orientation has a significant impact on the location and quantity of support structures, thus affecting material consumption and printing costs. This approach results in a 34% overall reduction in support structures compared to system-generated supports, resulting in a 13% reduction in material consumption and a 12% reduction in printing costs. The significance of this work lies in its ability to optimize the build orientation that can produce dental bridges with minimal support structures using MSLA. This research provides valuable insights for practitioners seeking to improve manufacturing efficacy and minimize support structures in dental manufacturing using 3D printing.