Industrial sla 3d printing

1) 2) 3)

1) A platform is placed in the tank with liquid photopolymer, at the same height from the resin surface.

2) The UV laser then selectively cures the required areas of the photopolymer resin according to a predetermined algorithm.

The laser beam is focused on a given path using a set of mirrors called galvos. Then the entire cross-sectional area of ​​the model is illuminated. Therefore, the resulting part is completely solid.

3) When one layer is finished, the platform moves to a safe distance and the mixing foot inside the tub mixes the resin.

This process is repeated until the part is printed. After printing, the part is not fully cured and requires further post-processing under the UV lamp . At the end of UV illumination, the part acquires very high mechanical and thermal properties.

The liquid resin solidifies through a process called photopolymerization: during solidification, the monomer carbon chains that make up the liquid resin are activated by an ultraviolet laser and become solid, creating strong, inextricable bonds with each other.

The photopolymerization process is irreversible, and there is no way to convert the resulting parts back into a liquid state. When heated, they will burn, not melt. This is because the materials that are produced by SLA technology are made from thermoset polymers, as opposed to the thermoplastics that FDM uses.

On SLA systems, most print settings are set by the manufacturer and cannot be changed. The only inputs are the layer height and the part orientation ( last, locates the supports ).

The typical layer height in a SLA print ranges from 25 to 100 micron .

The lower the layer height, the more accurately the complex geometry of the model will be printed, but at the same time the printing time and the likelihood of failure will increase. A layer height of 100 microns is suitable for most common geometries and is the golden mean.

Another important parameter for the operator is the size of the platform. It depends on the type of SLA printer. There are two main types: orientation top to bottom and orientation from bottom to top .

In the first case, the laser is above the tank, and the part is face up. The platform sits at the very top of the resin vat and moves down after each layer is sintered.

In " bottom up " layout on SLA printers , the light source is placed under the resin tank (see picture above) , and the part is built upside down.

The tank has a transparent bottom with a silicone coating that allows the beam of light to pass through but prevents the cured resin from sticking. After each layer, the cured resin separates from the bottom of the tank as the platform moves up. This is called the sintering step.

The orientation " bottom to top " is mostly used in desktop printers like Formlabs. The " top - down " orientation is used in the industrial SLA printer .

Printers SLA " bottom-up " are easier to manufacture and operate, but the size of the possible print will be smaller, since the forces applied to the part during the sintering stage can cause printing to fail.

Top-down printers, on the other hand, can print very large parts without much loss in accuracy. The wide possibilities of such systems naturally cost more.

The following are the main characteristics and differences between the two orientations:

Popular brands:

FORMLABS

Printable area: Up to 145 x 145 x 175 mm

Typical layer height and print accuracy: 25 to 100 µm and ± 0. 5% (lower limit: ± 0.010 to 0.250 mm) respectively

Popular brands:

PRISMLAB

Print area size: Up to 1500 x 750 x 500 mm

Typical layer height and print accuracy: 25 to 150 µm and ± 0.15% (lower limit ± 0.010 to 0.030 mm) respectively

Supports are always required at Print SLA . Structural structures are printed from the same material as the part and must be manually removed after printing.

Part orientation determines the location and amount of supports. It is recommended that the part be oriented so that surfaces that require maximum quality do not come into contact with supports.

In different types of SLA printers, support is used in different ways:

For top - down printers , support requirements are the same as FDM . They are essential for accurate printing of overhangs and bridges ( the critical overhang angle is typically 30 degrees ).

The part can be oriented in any position and is usually printed flat to minimize the number of supports and the total number of layers.

In printers like " from bottom to top " everything is more complicated. Overhangs and bridges also need to be supported, but minimizing the cross-sectional area of ​​each layer is the most important criterion.

Forces applied to the part during the sintering step can cause it to come off the platform. These forces are proportional to the cross-sectional area of ​​each layer.

For this reason, the parts must be oriented at an angle, and minimizing supports here is not a primary concern.

On the left - a detail oriented on the SLA printer "from top to bottom" (support minimization).

On the right is a part oriented on the SLA printer "from the bottom up" (minimizing the cross-sectional area).

Removing supports for an SLA printed part

One of the biggest problems with the accuracy of parts made with SLA is curling. This problem is similar to the deformation in FDM when materials shrink.

During curing, the resin shrinks slightly when exposed to the printer's light source. When shrinkage is significant, large internal stresses develop between the new layer and the previously cured material, causing the part to twist.

SLA printed parts have isotropic mechanical properties. This is due to the fact that one pass UV beam is not enough to completely cure the liquid resin.

Further passes help the previously hardened layers to fuse together. In fact, in the SLA of printing, curing continues even after the printing process is complete.

To achieve the best mechanical properties, parts printed using this technology should be post-cured by placing them in a chamber under intense ultraviolet radiation ( and sometimes at elevated temperatures ).

This greatly increases the hardness and heat resistance of SLA , but does not make it stronger. Rather the opposite.

For example.

materials

Photopolymer resins (thermosetting

materials)

Dimensional accuracy

± 0.5% (lower limit: ± 0.10 mm) - domestic
± 0.15% (lower limit ± 0.01 mm) - industrial

typical size

print area

Up to 145 x 145 x 175 mm - for desktop printers
Up to 1500 x 750 x 500 mm - for industrial

Total layer thickness

25 - 100 µm

Support

Always required

(Needed to make an accurate part)

• SLA print is best for producing visual prototypes with very smooth surfaces and very fine detail.

• Desktop SLA 3 D The printer is ideal for making small, about the size of an adult's fist, injection molded parts. Moreover, such a printer can be purchased at an affordable price.

• Industrial SLA 3 D printers can produce very large parts (up to 1500 x 750 x 500 mm)

Well, that's all we have! Thank you for being with us, see you soon. Further it will be more interesting!

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The Complete Guide to Stereolithographic (SLA) 3D Printing

Stereolithographic (SLA) 3D printing is gaining immense popularity due to its ability to produce highly accurate, isotropic and waterproof prototypes and models with fine details and smooth surfaces from a variety of modern materials.

This comprehensive guide explains how SLA printing technologies work, why thousands of professionals use them today, and how this 3D printing technology can be useful in your work.

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The development of 3D printing technology continues to influence how companies approach prototyping and manufacturing. This technology is becoming more accessible, and equipment and materials are developing in accordance with the possibilities and requirements of the market. That's why today designers, engineers and others are integrating 3D printing into workflows at all stages of development.

3D printing is helping industry professionals reduce recruitment costs, accelerate iteration, streamline manufacturing processes, and even discover entirely new business models.

Stereolithographic 3D printing technology has evolved significantly. In the past, resin 3D printers were monolithic and costly, requiring skilled technicians and costly service contracts to operate. Today's small desktop printers are highly flexible and produce industrial-quality products at a much lower cost.

Stereolithography is a type of additive manufacturing. It is also known as photopolymerization in the bath or 3D printing using polymer resin. Devices that use this technology have a common principle of operation: under the influence of a light source (laser or projector), a liquid polymer turns into a solid plastic. The main differences are in the location of the main components such as the light source, work platform and resin tank.

See how stereolithography 3D printing is done.

Stereolithographic 3D printers use light-sensitive curable materials called "polymers". When stereolithographic polymers are exposed to specific wavelengths of light, short molecular chains join together causing the monomers and oligomers to polymerize into either rigid or flexible patterns.

Graphical representation of the main mechanisms of stereolithographic 3D printing.

Models printed on SLA printers have the highest resolution and accuracy, the sharpest detail, and the smoothest surface of any 3D printing technology, but the main advantage of this method is its versatility.

Materials manufacturers have developed innovative formulas for stereolithographic polymers with a wide range of optical, mechanical and thermal properties similar to standard, engineering and industrial thermoplastic resins.

Comparison of 3D stereolithography with two other common plastic modeling technologies: Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS).

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Learn how to go from design to 3D printing with a Form 3 3D printer. Watch this 5-minute video to learn the fundamentals of using a Form 3 printer, from software and materials to processes printing and post-processing.

Use any CAD software or 3D scan data to design the model and export it to a 3D print file format (STL or OBJ). All printers based on SLA technology work with software that allows you to set print parameters and separate the digital model into layers. After the settings are complete, the model preparation software sends instructions to the printer via a wireless or cable connection.

More advanced users can design directly for SLA technology or, for example, print models with voids to save materials.

After a quick check of the settings, the printing process begins. The printer may run unattended until printing is complete. In printers with a cartridge system, material is replenished automatically.

Formlabs' online Dashboard allows you to remotely manage printers, resins, and employee access.

After printing is completed, models should be rinsed with isopropyl alcohol to remove resin residue from their surface. After the washed models have dried, some materials require final polymerization, a process that ensures the best possible strength and stability of the parts. Finally, remove the support structures from the models and sand down the remaining traces of the supports for a clean finish. Models produced with SLA technology can be machined, primed, painted or assembled depending on the intended use.

Final polymerization is especially important for functional polymer resins used in engineering, dentistry and jewellery.

Engineers, designers, fabricators and others choose 3D stereolithography because it provides excellent detail, smooth surfaces, superior model fidelity, isotropy, and water resistance. In addition, it allows you to work with various materials.

Because 3D printing creates models layer by layer, the strength of finished parts can vary depending on the orientation of the part relative to the printing process: the X, Y, and Z axes will have different properties.

Extrusion-based 3D printing processes such as deposition filament modeling (FDM) are anisotropic due to a special approach to creating different layers during the manufacturing process. This anisotropy limits the application of FDM technology or requires additional changes in the design of the model to compensate for it.

Check out our detailed guide comparing FDM vs. SLA 3D printers to see how they differ in terms of print quality, materials, application, workflow, speed, cost, and more.

Stereolithographic 3D printers, on the other hand, allow the production of highly isotropic models. Achieving detail isotropy relies on a number of factors that can be tightly controlled by integrating the chemical composition of materials with the printing process. During printing, the components of the polymers form covalent bonds, but when creating subsequent layers, the model remains in an "immature" state of partial reaction.

When immature, the resin retains polymerizable groups that can form bonds between layers, giving the model isotropic and waterproof properties after final curing. At the molecular level, there are no differences between the X, Y, and Z planes. This results in models with predictable mechanical characteristics critical for applications such as jigs and fixtures and finished parts, as well as functional prototyping.

SLA printed parts are highly isotropic compared to FDM parts.

Due to their isotropic nature, stereolithographically printed models, such as this jig for Pankl Racing Systems, can withstand directional loads during the manufacturing process.

SLA printed objects are continuous, whether they are solid or have internal channels. Watertightness is important when it is necessary to control and predict the impact of air or liquid flows. Engineers and designers are using the water resistance of stereolithography printers for air and fluid flow applications in the automotive industry, biomedical research, and to test the design of parts in consumer products such as kitchen appliances.

OXO relies on the water resistance of stereolithographic printed models to create durable working prototypes of air and liquid products such as coffee makers.

Stereolithographic 3D printing is used to produce precise, reproducible components in a variety of industries, including dentistry and manufacturing. In order to produce accurate models during the printing process, many factors must be strictly controlled.

The quality of stereolithographic 3D printing is somewhere between standard and precision machined. SLA has the highest tolerance compared to other commercial 3D printing technologies. Learn more about tolerances, accuracy and precision in 3D printing.

The heated resin tank combined with the closed working environment provide nearly the same conditions for every model. The higher accuracy also depends on the lower printing temperature compared to thermoplastic-based technologies in which the raw material is melted. Because stereolithography uses light instead of heat, it prints at close to room temperature and models are not subject to thermal expansion and contraction.

Dental example (comparing a scanned component to an original CAD model) demonstrating the ability to maintain tight tolerances for an entire stereolithographic model.

LFS stereolithography 3D printing involves an optic in a Light Processing Unit (LPU) that moves along the X axis. A single galvanometer positions the laser beam in the Y direction and then guides it along the deflection parabolic mirrors so that it is always perpendicular to the plane of the platform, so it always moves in a straight line, ensuring maximum precision and accuracy. This allows consistency to be achieved as the size of the equipment increases, for example, when working with a large-sized Formlabs Form 3L stereolithography printer. The LPU also uses a spatial filter, which forms a clear laser spot.

The characteristics of the individual materials also play an important role in ensuring the reliability and reproducibility of print results.

Formlabs Rigid Resin has a high green modulus, or modulus of elasticity, before final polymerization, allowing you to print very thin models with high precision and reliability.

Stereolithography printers are considered the best 3D printers due to the smooth surface of the produced models, the appearance of which is comparable to parts produced by traditional methods such as machining, injection molding and extrusion.

This surface quality is ideal when a perfect finish is needed and also helps reduce post-processing time because it is easy to sand, polish and paint. For example, large companies like Gillette use stereolithography 3D printing to create finished products such as razor handles in their Razor Maker platform.

Large companies such as Gillette use stereolithography 3D printing to create finished products such as razor handles in their Razor Maker platform.

The z-layer height is often used to determine the resolution of a 3D printer. On Formlabs stereolithographic 3D printers, it can be adjusted from 25 microns to 300 microns to trade off speed and print quality.

FDM and SLS printers typically print Z-axis layers between 100 and 300 microns wide. At the same time, a part printed with 100 micron layers on an FDM or SLS printer is very different from a part printed with 100 micron layers on an SLA printer. Models printed on a stereolithographic printer have a smoother surface immediately after printing, because their outer walls are straight, and each new printed layer interacts with the previous one, smoothing out the effect of the stairs. When printed on an FDM printer, layers are often visible in models, and the surface of models printed on an SLS printer has a grainy structure due to sintered powder.

In addition, the stereolithography printer can print fine details: the Form 3 laser spot size is 85 microns, while industrial SLS printers have a laser spot size of 350 microns, and FDM-based devices use nozzles with a diameter of 250– 800 microns.

Models printed on FDM printers often show layer lines and may have inaccuracies around complex features. Models printed on stereolithography printers have sharp edges, a smooth surface, and almost imperceptible layer lines.

The advantage of SLA polymers lies in a wide range of formulations offering a variety of characteristics: they can be soft or hard, contain additives such as glass and ceramics, or have special mechanical properties such as high bending temperature under load or impact resistance. Materials can be designed for a particular industry, such as dentures, or have properties close to those of final materials to create prototypes that can be tested and run under stress.

Ceramic Resin can be 3D printed with a stone-like texture and then fired to create a ceramic product.

In some cases, it is this combination of versatility and functionality that is leading businesses to use polymer-based 3D printing in-house. After solving existing problems through the use of a certain functional polymer, other applications are usually quickly discovered. In this case, the printer becomes a tool for discovering the various properties of different polymers.

For example, hundreds of engineers in the Design and Prototyping group at the Advanced Manufacturing Equipment Research Center (AMRC) at the University of Sheffield have access to 12 stereolithographic 3D printers and various construction materials that they use in numerous research projects for these partner companies. like Boeing, Rolls-Royce, BAE Systems and Airbus. They printed High Temp Resin washers, brackets, and a mounting system for a sensor that must operate in high temperature conditions, and used Durable Resin to create complex spring components for a material handling robot as part of a composite manufacturing automation system.

AMRC engineers have access to 12 stereolithographic 3D printers and various construction materials, allowing them to create custom-designed parts for a variety of research projects, such as brackets for a stacking robot (above) and mounts for an environmental sensor. high temperature (below).

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Stereolithographic 3D printing makes it easier for businesses across industries to innovate. Such industries include engineering, manufacturing, dentistry, healthcare, education, entertainment, jewelry, and audiology.

Rapid prototyping with 3D printing enables engineers and developers to turn ideas into working proofs of concept, transform concepts into high-quality prototypes that look and work like final products, and take products through testing phases to launch into mass production.

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By creating the necessary prototypes and 3D printing special tools, molds and production aids, manufacturing companies can automate production and optimize workflows at a much lower cost and in much faster time than traditional manufacturing. Thus, production costs are reduced and defects are prevented, quality is improved, assembly is accelerated and labor productivity is increased.

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Digital Dentistry reduces the risks and uncertainties associated with human error, enabling consistent quality and precision at every step of the workflow, and improving patient care. 3D printers can produce a range of high quality custom products at low cost, providing exceptional fit and reproducible results.

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3D printers are multifunctional tools for creating immersive learning and research environments. They stimulate creativity and introduce students to professional-level technology, enabling the implementation of the STEAM method in the fields of science, technology, art and design.

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Affordable, professional-grade desktop 3D printers help clinicians create medical devices that meet individual needs and improve patient outcomes. At the same time, the organization significantly reduces time and money costs: from laboratories to operating rooms.

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High resolution printed physical models are widely used in digital sculpting, 3D character modeling and prop making. 3D-printed models have been featured in animated films, video game characters, theatrical costumes, and even special effects for blockbuster films.

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Professional jewelers use the power of CAD and 3D printing to rapidly prototype, customize jewelry to customer specifications and produce large batches of blanks for casting. Digital tools allow you to create dense, highly detailed models without the tedious, error-prone production of stencils.

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Hearing professionals and hearing care labs use digital workflows and 3D printing to simplify the production of high-quality custom and hearing aids, as well as to mass-produce behind-the-ear hearing aids, hearing protectors, custom earmoulds and headphones .

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Many companies are starting to use 3D printing technology through service bureaus and laboratories. Outsourcing can be a great solution when the need for 3D printing is infrequent or you need to do one-off jobs using materials that have unique properties or produce special models. Service bureaus can also provide advice on various materials and offer additional services such as design or improved finishes.

The main disadvantages of outsourcing are the high cost and duration of production. Often, outsourcing becomes a step on the way to in-house production as needs grow. One of the main advantages of 3D printing is its speed compared to traditional production methods. But it is noticeably reduced when the delivery of the model produced by the involved organization takes several days or even weeks. As demand and production capacity increase, the costs of outsourcing are rising rapidly.

With the increasing availability of industrial-quality 3D printing today, more companies are opting to immediately bring 3D printing into their facility, vertically integrating it into existing workshops or labs, or providing printers to engineers, designers, and other professionals who benefit from digital transformation. projects into physical models or are engaged in the production of products in small batches.

Compact desktop stereolithography 3D printers are an excellent solution for rapid model production. Depending on the number of parts needed and the volume of prints, the investment in a compact 3D printer can pay for itself in just a few months. In addition, compact appliances allow you to purchase just the amount of equipment you need to run your business and scale your production by adding more units as demand grows. Using multiple 3D printers also allows you to print models from different materials at the same time. And when the need arises for the production of large parts or the use of non-standard materials, service bureaus can come to the rescue.

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High production speed is an important argument in favor of purchasing a desktop 3D printer. When working with a print bureau, there are delays related to the speed of production, communication and delivery. A desktop 3D printer like the Form 3 delivers models in hours, allowing designers and engineers to print multiple parts a day. This contributes to faster iterations and significant time savings in product development, as well as rapid testing of mechanisms and assemblies, avoiding costly tool changes.

Purchasing a desktop 3D printer saves a lot of money by eliminating bureau services and traditional processing methods, as their cost rises sharply with demand and production volumes.

For example, a production engineer and others at Pankl Racing Systems used stereolithographic 3D printing technology to produce products on a tight schedule. This allowed them to independently manufacture custom-designed jigs and other small-sized components for the production line. While stereolithography was initially viewed with skepticism, this technology proved to be an ideal solution to replace the machining of a number of tools. In one of the cases, it made it possible to reduce the manufacturing time of conductors by $51-$137

By 3D printing custom-designed jigs, Pankl Racing Systems has significantly reduced both order preparation time and production costs.

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