Process-Failure-Mode-and-Effects Analysis for Vat Photopolymerisation: State Variables, Detection and Control Priority

A useful process FMEA for vat photopolymerisation should describe how process states fail, not merely list visible print defects. Delamination, undercure, dimensional growth, brittle failure or contamination can arise from several mechanisms and therefore require different controls. This review develops a PFMEA architecture that maps process steps to functions, failure modes, effects, causes, existing prevention controls and detection controls. Severity belongs to the effect; occurrence belongs to the causal process state; detection belongs to the control system. The review uses the harmonised AIAG/VDA FMEA logic as a methodological reference while adapting the content to photopolymer-specific variables such as resin age, spectral dose, working curve, separation forces, wash state and post-cure. Control priority is not reduced to multiplying three ordinal numbers; high-severity failures with weak prevention remain visible even when a simple risk product would rank them lower. The central conclusion is that PFMEA becomes operational only when each high-priority causal variable is connected to a measurable control plan and reaction rule.

ER-295 · Version 0.3.