Research on the large-format splicing method for stamping-type digital light processing 3D printing

In response to the strong demand for the development of large-format digital light processing (DLP) 3D printing technology, traditional multi-ultraviolet (UV) fixed stitching methods face high costs and limited format sizes. This paper adopts a stamping DLP large-format stitching printing method, which achieves large-format DLP printing by intermittently moving a single UV projector in two axes. To address the stitching issues of the stamping DLP printing method, this paper divides the stitching area and derives the energy distribution principles that need to be followed at the adjacent printing seams. By introducing a normal distribution process and combining the projection function with energy distribution principles, a method for energy gradient distribution in the overlapping stitching area is proposed and experimentally validated. The experimental results show that the minimum dimensional error of the printed parts is − 0.0591, and the stitching hardness and tensile strength errors are 0.5 and 0.0092, respectively. Compared to traditional multi-UV fixed stitching methods, this study significantly improves printing performance while reducing costs. This strategy has broad application potential in large-scale industrial production and personalized manufacturing, particularly in enhancing production efficiency and reducing manufacturing costs.