In the current study, response surface method (RSM) was applied to correlate stereolithography (SLA) process parameters such as layer thickness, hatch overcure, and part orientation to SLA part characteristics such as density, surface finish and ultimate tensile strength (UTS). The results showed that density was directly proportional to the hatch overcure but inversely affecting the layer thickness. Besides, the hatch overcure was shown to have a positive effect on the UTS, while the layer thickness was found to influence the UTS adversely. Furthermore, the relationship between the layer thickness and surface roughness was suggested to be directly proportional. The optimised values of process parameters indicated by the response surface model were 90°, 0.12 mm and 0.1 μm for the part orientation, hatch overcure and layer thickness, respectively. The corresponding predicted density, UTS and surface roughness of an SLA part were 1,098 kg/m3, 42.8 MPa and 5.31 μm, respectively.

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