PDPM IIITDM Jabalpur October 5, 2024

Rapid Product Development Technologies RP/AM Processes

Since the presentation of first commercial application in 1987, a
Liquid Based RP/AM Techniques large number of processes have been developed. Now a days commonly
used RP processes includes:-
Liquid Based
Stereolithography (SLA)
Digital Light Printing (DLP)
Instructor: Dr. Prashant K. Jain Masked Stereolithography (mSLA)
Professor (ME Discipline) Solid Ground Curing (SGC)
PDPM Indian Institute of Information Technology, Solid based
Design and Manufacturing Jabalpur, Jabalpur, INDIA Laminated Object Manufacturing (LOM)
Resources: web.iiitdmj.ac.in/~pkjain/ Fused Deposition Modeling (FDM)
Email: pkjain@iiitdmj.ac.in, pkjain2006@gmail.com Powder based
http://www.iiitdmj.ac.in/Faculty/pkjain.html
Three-Dimensional Printing (3DP)
http://in.linkedin.com/in/pkjain2006
https://www.facebook.com/pkjain2006 Selective Laser Sintering (SLS)
Laser Engineered Net Shaping (LENS)
PDPM Selective Laser Melting (SLM)/(DMLS)
INDIAN INSTITUTE OF INFORMATION TECHNOLOGY,
DESIGN AND MANUFACTURING JABALPUR
(An Institute of National Importance (INI) established by MHRD, Govt. of INDIA) October 5, 2024 Dr. Prashant K. Jain (IIITDMJ) 7

Stereolithography (SLA) SLA

As the laser beam strikes the resin surface, the
liquid resin is hardened to a solid plastic
 One of the most widely used vat Scanning Laser
photopolymerization Mirror
technologies.
 Objects are created by selectively Re-
curing a polymer resin, layer by coating
layer. Blade Cured resin
Curing Process to form model
 Utilizes an ultraviolet (UV) laser
beam for the curing process
Materials
 Uses photosensitive thermoset
polymers
 Materials are in liquid form before
curing Liquid Resin

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SLA SLA

Source : Solid Concepts Source : FormLabs

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SLA SLA Process Workflow

Source : FormLabs
Source : FormLabs

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Materials used in SLA 3D printing process Materials used in SLA 3D printing process
 Photopolymer Resin: Photopolymer resin is the most commonly used material in SLA 3D
printing. It is a liquid material that is cured or solidified by light. Many photopolymer resins
are available, each with different properties, such as different colors, transparency, and
strength.
 Epoxy Resin: Epoxy resin is a type of material that is commonly used in SLA 3D printing. It is
known for its high strength, durability, and chemical resistance. General Purpose Resins Engineering and Manufacturing Resins
 Acrylate Resin: Acrylate resin is a type of material that is commonly used in SLA 3D printing.
It is known for its high transparency, low viscosity, and high toughness.
 Polyurethane Resin: Polyurethane resin is a type of material that is commonly used in SLA
3D printing. It is known for its high flexibility, impact resistance, and temperature
resistance.
 ABS-Like Resin: ABS-Like resin is a material that mimics the properties of ABS plastics. It is
known for its high strength, high-temperature resistance, and good mechanical properties.
Dental Resins Medical Resins Jewellery Resins
 Flexible Resin: Flexible resin is a type of material that is commonly used in SLA 3D printing.
It is known for its flexibility and resilience, making it ideal for creating flexible parts and
models.
Source : FormLabs
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Resin suppliers Dimensional Accuracy of SLA printer

 Dimensional Accuracy: SLA 3D printing is known for its high dimensional
accuracy, making it suitable for applications requiring precise details and
tight tolerances.
 Tolerance Level: The typical tolerance level for SLA 3D printed parts is ±0.1
mm, influenced by the configuration, orientation, and design of the print.
This is achieved through UV light curing of the resin.
 Resolution: The resolution of SLA 3D printing refers to the smallest feature
size that can be reliably produced, which depends on the laser's spot size
and the resin's reactivity.
 Feature Resolution: SLA 3D printing can produce very fine features, with
feature resolution as low as 0.05 mm (50 microns).
 Layer Thickness: The layer thickness typically ranges from 25 to 100
microns, offering flexibility in balancing detail and build speed, resulting in
a smooth surface finish comparable to injection-molded parts.
Source : zongheng3d.com Source : raise3d.com
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SLA: Advantages
SLA: Advantages/Disadvantages
 Advantages
 Good surface finish
 Complex geometry can be easily obtained
 Good accuracy of the geometry
 Versatile Material Options
 Large and Complex Part Production Print with unbeatable accuracy Large part of build volume 33.5 × 20 × 30 cm
 Disadvantages
 Post-Processing Requirements
 Models need support structures that must be removed as a
finishing operation
 Parts can warp, especially with acrylate resins
 Resins are hazardous and need careful handling
 High setup cost
 Mechanical Property Limitations Produce highly complex models

Rapid, small series production

Source: Additive X
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SLA: Advantages
SLA FDM SLA: Process parameters
Entry Level $300 $200
Intermediate $5,000 $2,000  Process parameters
Industrial $100,000 $5,000  Laser scanning velocity
Printer Cost Washing Parts  Bath temperature
SLA (SLA FDM (FDM  Thermal convection coefficient
resin) Filament)  Chamber temperature
$50 to $200 $20 to $50 per
 Laser Parameters
Per Liter kilogram  Laser power
Material Cost
Removing Supports Sanding and Polishing  Wavelength
When SLA Costs Make Sense  Beam radius
Despite higher gear and material costs, SLA can
deliver valuable results in certain situations:
 Material Properties
 Thermal conductivity
• Detailed prototypes where surface finish and
resolution are critical
 Absorptivity
• Low volume production of high margin products
Cleaning the Resin Vat
 Coefficient of thermal expansion
• Parts requiring complex geometry unattainable
through other processes
 Glass transition temperature
Source: ZONGHENG3D
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Sample parts SLA Applications

Jewellery making Hearing Aid

Prop-Making: Renfield (2023)

Dentistry

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SLA Applications
Manufacturers

• 3D Systems
• http://www.3dsystems.com/
• Formlabs
• http://formlabs.com/
• CMET
Injection molding • http://www.cmet.co.jp/eng/
• Shanghai Union Technology
• http://www.union-tek.com/
• Shaanxi Hengtong Intelligent Machine
• http://www.china-rpm.com/en/

Waterproof parts under pressure :

Functional Prototype Fiber Optics DEEPi camera by Brennan Phillips
Innovations
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3D systems 3DSystems- iPro 8000 MP

Power (nominal) at head- 1450 mW

(1000 mW at material surface
under nominal optical path
condition)
Spot Sizes- 0.13 mm (0.005 in) and
0.76 mm (0.030 in)
Maximum Part Drawing Speed- 25
m/sec (1000 ips)
Build Volume- 650 x 750 x 550 mm
Maximum Part Weight-75 kg

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Formlabs Form 3L Formlabs Form 1+

Build Volume- 335 × 200 × 320 Build Volume- 125 × 125 ×

mm 165 mm
Layer Thickness-25-300 microns Layer Thickness-25, 50, 100
(0.001-0.012 inches) microns (0.001, 0.002,
Min Feature Size- 300 microns 0.004 inches)
(0.012 inches)
Min Feature Size- 300
Laser Specifications- 2 Light
microns (0.012 inches)
Processing Unit EN 608251:2014
certified Class 1 Laser Product Laser Specifications- EN
405 nm optical wavelength Two 60825-1:2007 certified,
250 mW lasers 85 µm laser spot Class 1 Laser Product,
size 405nm violet laser

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Digital Light Processing (DLP) 3D Printing Type of DLP 3D Printers

 DLP 3D printer
 DLP uses a digital projector to cure
liquid photopolymer resin layer by
 Bottom-Up DLP 3D Printer
layer.
 This is a vat polymerization technique  Top-Down DLP 3D printer
similar to SLA (Stereolithography), but
DLP cures entire layer at once. Major difference between these two printers is the
site of light source and position of the model on
 A Digital Micromirror Device (DMD)
the build platform
reflects light from an LED or UV source
to solidify the resin.  In a bottom-Up DLP 3D printer, the light source
Digital Light Processing (DLP) 3D printing is positioned at the foot of the apparatus and
 The projector's image consists of
the model normal dangles(hangs) upside down
square pixels, forming small
rectangular bricks called voxels.  In a top-down DLP 3D printer, the light source
is placed at the tip of the device and the object
 Faster than SLA
Source : zongheng3d.com is formed on the build platform. Source : Carima.com
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DLP working principle DLP working principle (ANYCUBIC PHOTON MONO X)

Source: LIGHTNING3D
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DLP Resin materials Post Processing of DLP printed parts

 First, the accumulated and remaining liquid resin from the

 Clear Resins finished part is washed off using Isopropyl Alcohol
 Water-Washable Resins  The pliers are then used to cut the support structure exactly
 Flexible 3D Printing Resins at the touching point of an object
 Heat-Resistant Resins  It can also be separated by simply breaking them manually
 Burnout Resins and the remaining spots can be removed by sanding them
 Dental Resins  The layer adhesion of the DLP printed objects is accelerated
by exposing them to rays of light even after the printing
completion

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Challenges of Curling Sample printed through DLP (ANYCUBIC PHOTON MONO X)

 As we know that FDM printing is associated with Warping

risks, similarly DLP can also create a CURLING effect if
adequate measures are not taken during the solidification of
the Resin
 Curling is the shrinkage of the resin when exposed to UV light
rays. The shrinkage happens due to the internal stress build
up between the previous solidified layer and the new layer
 Another major cause for this problem is when the printed
part is kept in IPA(Isopropyl Alcohol- agent, used to clean up
the remnants of the resin) the post cured part becomes
curled

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Advantages of DLP 3D Printing Disadvantages of DLP 3D Printing

 The light source remains stagnant and at once solidifies the  Manufactured models should not be exposed to sunlight
complete resin layer as opposed to SLA otherwise they will degrade
 Parts with detailed structures can be manufactured with crisp  Parts are so strong and thus cannot be remolded or modified
edges covering minute details  DLP 3D printers run with more cost compared to other digital
 Printing speed is relatively higher due to the usage of Digital 3D printers
Projector light when compared to other vat polymerization  DLP uses photopolymer resin which are more expensive and
techniques such as SLA offer less material variety
 Intensity of the light source can be controlled by the operator  DLP printer typically have a smaller build volume due to the
 DLP produces objects that are super accurate with clearly size constraints of digital light projector
structured geometries

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Applications of DLP Comparison of DLP vs SLA

Dental industry Medical and healthcare
industry
 Energy source
• SLA uses UV laser beam
• DLP uses UV light from projector
 Light source movement
• In SLA laser beam moves from point to point DLP SLA
tracing the geometry Speed Fast Moderate
3D printed dental models, source: Prodways A batch of 3D printed hearing aids, source: Shining 3D • In DLP UV light source remains stationary and Accuracy High High
it cures the complete layer of resin at a time Finish Smooth Smooth
 Cost Quality
• SLA uses laser lights which are expensive Cost of High Moderate
Jewelry industry • DLP uses UV light source which is less Materials
Detailed ring printed on a DLP 3D expansive
printer. source: 3D Hubs

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Manufacturers Ultra 32 ( Asiga)

• Asiga
• https://www.asiga.com/ultra/
• b9creations  Build Volume X, Y, Z : 119 x
• https://www.b9c.com/products/b9-core-series
67 x 130mm (4.68 × 2.63 ×
• ETEC
• https://etec.desktopmetal.com/product/ 5.11 inches)
• FLASHFORGE  Pixel Size : 32µm
• https://industry.flashforge.com/product-detail/flashforge-
hunter-S-dlp-3d-printer  Material Compatibility : Use
• ANYCUBIC any one of over 500
• http://www.anycubic.com/
• SHINING 3D qualified resins from the
• https://www.shining3ddental.com/solution/accufab-l4d/ world’s leading material
manufacturer, or create
your own

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B9 Core 550 (b9creations) Envision One (ETEC)

 Print Dimensions : 180 x

 Print Dimensions :96 x 54 x 127mm 101 x 175 mm
 Print Speeds : 25-100+ mm/hr  XY resolution: 60 µm
 Effective Resolution with FAST :  Z resolution :50-150 µm
<25 µm
 Wavelength :405 nm

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Hunter S (FLASHFORGE) Photon Mono X 6ks (ANYCUBIC)

 Print Dimensions : 144 x 81 x

180 mm  Print Dimensions :
 Print speed : 10-50mm/h 200 x 195.84 x 122.4 mm
 Layer Height : 20-200μm  Print speed : 15-60 mm/h
 Pixel size: 75μm  Layer Height : 10-50 μm
 Wavelength: 405nm  Pixel size: 34 μm
 Wavelength: 405 nm

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AccuFab-L4D (SHINING 3D) Masked stereolithography (MSLA)

 MSLA uses an LCD screen to mask

 Print Dimensions : light and cure liquid photopolymer
192x 120 x 180 mm resin layer by layer.

 Print speed : Max 50 mm/h  This vat polymerization technique

is similar to SLA but cures entire
 Layer Height : 50-100 μm layers simultaneously, speeding up
 Pixel size: 50 μm the process.

 Wavelength: 405 nm  A UV light passes through an LCD

screen, selectively hardening resin
according to the digital mask. Each
pixel on the screen forms a small
rectangular voxel, allowing for
precise layer creation.
Source : formlabs
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mSLA process video mSLA materials (Resins)

 Standard resin
 Elegoo Standard Resin, Nova 3D Nova Stan, PrimaCreator Value)
 Water Washable
 Elegoo Water Washable, Phrozen Water Washable, eSun Water
Washable
 ABS like
 Elegoo ABS-Like, Phrozen ABS-like

 High Detail/ Modeling

 Ameralabs AMD-3, Schichtwerkstatt Fast, Sirata Tech Sculpt

 Eco/Bio
 Anycubic Plant Based, eSun eResin-PLA-BIO

 Tough/Engineering
 Monocure TUFF, Liqcreate Strong-X, Siraya Tech blu

Source: Structo 3D
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Advantages of mSLA Disadvantages of mSLA

 High detail: mSLA is known for its ability to capture intricate designs with a
 Costly materials: Photopolymer resins used in mSLA can be more
high level of precision. The resin used in mSLA 3D printing has a high
expensive than the materials used in other 3D printing methods. However,
resolution, allowing it to create more intricate designs with sharper edges
while material costs can be a bit higher, printing with resin allows for
and finer details.
higher-quality prints at faster speeds–making them well worth the initial
 Dimensional accuracy: This high-resolution capability also allows for better investment.
layer heights, meaning that the layers of the 3D-printed object can be
 Handling of materials: The uncured resin and the chemicals used in post-
thinner and more precise. It also provides excellent dimensional accuracy,
processing can be toxic and should always be handled with care.
which is critical in industries like engineering and healthcare.
 Post-processing: mSLA prints may require a significant amount of post-
 Speed: Since mSLA cures an entire layer of resin at once, it can often
processing, which can be time-consuming.
complete prints faster than traditional SLA, particularly for larger models.
 Warping can occur on large and improperly supported prints
 Excellent surface finish: The prints from an mSLA printer often have a
smooth and high-quality surface finish. The thinner layers created by the
high-resolution resin result in a smoother surface finish.
 Quiet printer operation
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Applications of mSLA Applications of mSLA

 Dental and medical applications: mSLA’s precision and the availability of  Jewelry design: The high level of detail achievable with mSLA makes it ideal for
biocompatible resins make it a good fit for dental aligners, surgical guides, creating intricate jewelry designs.
and other medical devices.  Product packaging: mSLA 3D printing also finds utility in product packaging. For
 Automotive aftermarket production: mSLA 3D printing has also example, PepsiCo used Nexa3D’s xPEEK147 from Henkel Loctite to produce
revolutionized automotive aftermarket production. For instance, a company sturdy mold inserts for their packaging needs. The Nexa3D NXE 400 3D printer
like R3D used just a single NXE 400 printer to manufacture 18,000 parts for not only reduced the production time to a mere 12 hours for a complete mold
set but the resulting molds could also be used for more than 10,000 bottles
1,000 police cars in a year, showcasing the potential of this technology in
before failure.
large-scale production.
 Acoustic instruments: Even the music industry is not left untouched by the
 Product prototyping: The excellent surface finish and dimensional accuracy of
mSLA revolution. Innovators like Liquid Sound Tech have successfully used
mSLA prints are beneficial for prototyping and model testing.
engineering material from Nexa3D, such as xCE, to create and extensively stress
 Large-scale 3D printing service providers: Large-scale 3D printing service test acoustic instruments, demonstrating the robustness and versatility of mSLA
providers like MTB3D are also benefiting from mSLA technology. Solutions 3D printing.
like XiP enable these providers to produce high-quality parts with unmatched  Miniatures and model making: mSLA is increasingly being used to create highly
throughput and expand their service capabilities and customer base. detailed miniatures for tabletop games and model making.
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Manufacturers Mars 4 Ultra (Elegoo)

• Elegoo
• https://www.elegoo.com/products/  Print volume size:
• Phrozen 153.36×77.76×165 mm
• https://phrozen3d.com/products/sonic  Layer Thickness: 0.01-0.2 mm
• Prusa3d  Average Printing Speed: 150
• https://www.prusa3d.com/
mm/hr

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Phrozen Sonic Mega 8K S 15" LCD 3D Printer Original Prusa SL1S SPEED 3D printer

 Print volume size:  Print volume size: 127×80×150 mm

330×185×300mm  Minimal layer height: 0.01 mm
 Layer Thickness: 0.01-  Supported materials UV sensitive liquid
0.30 mm resin (405nm),
 XY Resolution: 43 µm
 Average Printing
Speed: 400 layers/hr

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Solid Ground Curing (SGC) Solid Ground Curing (SGC)

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Process Video SGC: Advantages/Disadvantages

Advantages:-
 Solid ground curing system does not require a support
structure since wax is used to fill the voids.
 The model produced by SGC process is comparatively
accurate in the Z-direction because the layer is milled
after each light-exposure process.
Disadvantages:-
 It produces too much waste and its operating costs are
comparatively high due to system complexity.

Source : Cubital
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SGC: Process parameters

SGC: Manufacturers
 Irradiation medium
 XY resolution
 Elevator vertical resolution • Cubital Inc.
 Other Features • http://www.wtec.org/loyola/rp/p1_cubit.htm
 Surface Definition
 Minimum feature size
 Work volume XYZ
 Production Rate
 Minimum layer thickness
 Dimensional accuracy
 Data control unit
 Power supply

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Cubital solider SGC5600 SGC: Sample parts

Maximum Build Envelope:

500x350x500 mm
(20x14x20")
X-Y Resolution:
0.084 mm (0.0033")
Z Resolution (layer
thickness): 0.1 - 0.2
mm(0.004 - 0.006")
Typical minimum Feature
Size- 0.4 mm (0.016")

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