In order to explore the effect of printing parameter configurations on the forming performance of Digital Light Processing (DLP) 3D printed samples, printing experiments were carried out on the enhanced adhesion and efficient demolding of DLP 3D printing devices. The molding accuracy and mechanical properties of the printed samples with different thickness configurations were tested. The test results show that when the layer thickness increases from 0.02 mm to 0.22 mm, the dimensional accuracy in the X and Y directions increases first and then decreases, while the dimensional accuracy in the Z direction decreases, and the dimensional accuracy is the highest when the layer thickness is 0.1 mm. The mechanical properties of the samples decline with an increasing layer thickness of the samples. The mechanical properties of the 0.08 mm layer thickness are the best, and the tensile, bending, and impact properties are 22.86 Mpa, 48.4 Mpa, and 35.467 KJ/m², respectively. Under the condition of ensuring molding accuracy, the optimal layer thickness of the printing device is determined to be 0.1 mm. The analysis of the section morphology of samples with different thicknesses illustrates that the fracture of the sample is a river-like brittle fracture, and there are no defects such as pores in the section of samples.

Additive Manufacturing (AM) is a digital manufacturing method that creates structures by adding material layer by layer. This approach offers simplicity, speed, and efficiency. Additive manufacturing methods can process wood-plastic composites, but they are often limited by poor surface quality, low interfacial bonding, and the requirement for complex post-processing. In this study, walnut shell and photosensitive resin were used to fabricate wood-plastic composite specimens with varying walnut shell powder contents using DLP technology. The properties analyzed included dimensional shrinkage, mechanical strength, double bond conversion rate, and microstructure. The results indicated that as the walnut shell content increased, the dimensional shrinkage of the formed parts initially decreased and then increased, reaching the minimum value of 0.631% at 12% walnut shell powder content. SEM imaging revealed that resin infiltrates the particle pores, forming a network structure that enhances mechanical performance. Tensile and flexural strengths also reached their peak values at 8% content, measuring 17.7 and 45.4 MPa, respectively, while impact strength decreased with increasing walnut shell content.

By combining numerical simulation and experimental testing, the powder bed model was imported into the discrete element software Flow-3D as the initial model to analyze the melting, flow, and solidification processes of powder particles. The study examined the effects of different laser powers, scanning speeds, and energy densities on single-track sintering paths and temperature fields. It described the characteristics of stable, metastable, and unstable sintering pools and discussed the impact of different laser power levels and various parameter combinations at the same energy density on the width and depth of the sintering pool.. It was found that when the laser power is 10W and the scanning speed increases from 1400mm/s to 2200mm/s, the sintering path morphology deteriorates from a stable to a semi-molten state. At a scanning speed of 2000mm/s, as the laser power increases from 8W to 14W, the width and depth of the sintering pool increase. When the laser energy density is constant at 10J/m, there are significant differences in the sintering path formation under different laser power and scanning speed combinations, with the width of the sintering pool increasing as the laser power and scanning speed increase.