Integrated assessment of mechanical properties and environmental footprint in MSLA 3D printing

Abstract Masked Stereolithography is an additive manufacturing technology widely adopted for industrial and biomedical applications due to its high accuracy and surface quality. Nevertheless, the combined effects of process parameters on mechanical performance and environmental sustainability remain insufficiently explored. This study presents an integrated assessment of the mechanical properties and environmental impacts of printed components, aiming to identify optimal printing conditions. Specimens were produced using a commercial photocurable resin by varying exposure time (4–12 s), layer thickness (0.01–0.09 mm), and LED light intensity (50–100%), following a Box–Behnken Design of Experiments with 15 printing conditions. Tensile and flexural properties were evaluated according to ASTM D638 and ASTM D790 standards, while energy consumption during printing and post-processing was experimentally measured. Non-linear multiple regression models were developed to predict mechanical properties and energy consumption, and a cradle-to-gate Life Cycle Assessment was performed in compliance with ISO 14040–44 standards using Global Warming Potential as the impact category. Results indicate that longer exposure times and higher LED intensities improve tensile and flexural strength and stiffness by enhancing polymer cross-linking, although diminishing returns occur at higher levels. Reduced layer thickness increases mechanical performance but leads to higher energy consumption and environmental impacts due to extended printing times. The regression models showed high predictive accuracy (R 2 > 96%, MAPE < 8%). Life Cycle Assessment results reveal that the material phase contributes up to 90% of total environmental impacts, while intermediate layer thicknesses (~ 0.05 mm) provide the best trade-off between mechanical performance and sustainability. This work provides practical guidelines for optimizing Masked Stereolithography process parameters toward sustainable additive manufacturing.