Mask Projection Stereolithography is a high resolution manufacturing process that builds parts layer by layer in a photopolymer. A MPSLA system is designed and assembled. The irradiance incident on the resin surface when a given bitmap is imaged onto it is modeled as the Irradiance model. Print-through errors occur in multi-layered builds because of radiation penetrating beyond the intended thickness of a layer, causing unwanted curing. In this research, the print through errors are modeled in terms of the process parameters used to build a multi layered part. To this effect, the Transient layer cure model is formulated, that models the curing of a layer as a transient phenomenon, in which, the rate of radiation attenuation changes continuously during exposure. The print through model is used to formulate a process planning method to cure multi-layered parts with accurate vertical dimensions. The models formulated and validated in this work are used to formulate a process planning method to build MPSLA parts with constraints on dimensions, surface finish and build time. The process planning method is demonstrated by means of a case study.

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