High-Quality
Digital Light Processing
Parts
Parts in 1 to 4 days.
Digital Light Processing (DLP) is used for:
- Part Consolidation
- High Detail and Excellent Surface Finish
- Isotropic Mechanical Properties
Quality Matters | AS9100D Certified, ISO 9001:2015, ISO 13485:2016, & ITAR Registered
*Not all locations have all certifications and registrations. Parts requiring these will be made at facilities with the correct credentials.
Table of Contents
What is Digital Light Processing?
Digital Light Processing (DLP) is a form of 3D printing that uses a UV-sensitive liquid resin cured through a digital light projector. Once the printing process is finished, our AM technicians clean the part, remove any supports, and subject it to UV and thermal curing if needed.
DLP 3D printing is particularly suitable for projects requiring high levels of detail and finishing in various production-grade materials. This technology can produce components with various durometers and characteristics, from supple silicone to rigid high-temp cyanate ester. It is an excellent choice for small end-use components, lightweight metal part replacements, functional, high-detail prototypes, jigs, and fixtures.
How does Digital Light Processing work?
An AM Technician uploads your CAD file into the machine, and the software breaks it down layer by layer. We also consider the build’s direction and the supports’ placement. The Digital Light Processing machine uses a photochemical process by projecting light into a UV-curable resin. The build platform rises after the light solidifies each layer. These steps repeat until the build is complete.
After the DLP printer, an AM technician manually removes the component from the platform and support structure. The part is then cured to its final mechanical properties by utilizing a post-curing apparatus (PCA) or forced-circulation oven before moving on to the final surface finishing.
Advantages to Digital Light Processing
Digital Light Processing technology has revolutionized the way products are designed and manufactured. The following are a few of the advantages of digital light processing:
- Excellent surface quality.
- Materials diversity.
- Very accurate.
- Ideal for dyeing, coloring, and other finishes.
Disadvantages to Digital Light Processing
While there are a lot of advantages to digital light processing, there are also some disadvantages to consider:
- Supports are needed.
- Over time materials can become brittle.
- Not suitable for outdoor uses, not UV stable.
Digital Light Processing at Prototek
OEM:
Carbon
Max Build Area:
7.4 x 4.6 x 12.8 in
Lead Time:
1 – 4 Days – Depending on materials.
Material:
EPU 40 & 41, EPX 82 & 86FR, FPU 50, LOCTITE® 3D IND405 Clear, MPU 100, RPU 70 & 130, SIL 30, UMA 90
Tolerances:
UMA 90: ± 0.005 in for the first inch and ± 0.002 in for each additional inch.
Two-part engineering materials depend on the geometries.
Layer Thickness:
Standard Resolution: 0.004 in
Fine Resolution: 0.002 in
Ultra Fine Resolution: 0.001 in
Prototek's Materials
Material
Description
Characteristics
More Information
EPU 40
Elastomeric Polyurethane
It is a high-performance elastomer with excellent elastic recovery, tear resistance, and high impact strength. It is an ideal material for producing durable and flexible parts, such as gaskets and seals.
- Black
- Biocompatible*
- Chemical Resistant
- Elastomeric
- Flexible
- Impact Resistant
- Tear and Wear Resistant
EPU 41
Elastomeric Polyurethane
It is an elastomeric polyurethane material with superior flexibility, durability, resilience, tear resistance, and elongation properties. It is an ideal choice when toughness and reliability are essential.
- Black
- Biocompatible*
- Chemical Resistant
- Elastomeric
- Fatigue Resistant
- Flexible
- Impact Resistant
- Wear and Tear Resistant
EPX 82
Epoxy
It can produce parts with exceptional stiffness and strength and withstand high temperatures and harsh environments. Additionally, it can be easily post-processed to add features like threaded inserts and other secondary operations.
- Black
- Good for Snap Fits
- High Strength
- Impact Resistant
- Rigid
- Temperature Resistant
EPX 86FR
Flame Retardant Epoxy
The material is resistant to chemicals and has high thermal conductivity, enabling it to withstand harsh environments. Its flame-retardant properties make it suitable for use in parts that require compliance with flame retardancy standards, such as in the aerospace and automotive industries.
- Black
- Chemical Resistant
- Flame Retardant
- Good for Snap Fits
- High Strength
- Impact Resistant
- Rigid
- Temperature Resistant
FPU 50
Flexible Polyurethane
It is a highly durable DLP material with excellent resistance to abrasion and impact, making it ideal for producing parts and products that require flexibility and strength. The material has a Shore A hardness of 50, which means it has moderate flexibility while maintaining its shape. This material is also able to withstand high temperatures and chemical exposure.
- Black
- Abrasion Resistant
- Fatigue Resistant
- Good for Snap Fits
- High Strength
- Impact Resistant
- Wear and Tear Resistant
LOCTITE® 3D IND405 Clear is a clear/translucent, photoreactive resin for 3D printing. This material offers high-resolution printing capabilities with fast cure times. A versatile formulation, it is suitable for a wide range of applications in industries such as medical, consumer goods, and automotive. Its high elongation and toughness make it resistant to cracking under stress.
- Clear/Translucent
- High Strength
- Impact Resistant
- Rigid
Medical Polyurethane
It is a high-performance thermoplastic material designed for the healthcare industry. This material possesses exceptional strength, durability, and chemical resistance, making it ideal for medical equipment and devices.
- White
- Abrasion Resistant
- Biocompatible*
- Chemical Resistant
- High Detail/High Resolution
- High Strength
Rigid Polyurethane
This digital light processing material possesses high stiffness, good tensile strength, and impact resistance properties, which make it ideal for applications that require parts with high durability and structural integrity. RPU 70 has a Shore D hardness rating of 70 and provides excellent resistance to abrasion, chemical exposure, and wear and tear.
- Black
- Biocompatible*
- Flame Resistant
- Good for Snap Fits
- High Ductility
- High Strength
- Rigid
- Temperature Resistant
Rigid Polyurethane
It offers high print accuracy with superior mechanical properties, including excellent stiffness, toughness, and impact resistance. It has a high heat deflection temperature of up to 120°C, meaning it can withstand high-temperature applications without degrading.
- Black
- High Strength
- Impact Resistant
- Rigid
- Temperature Resistant
Silicone
This material is highly compatible with the human body and has excellent elongation and tear strength, making it a perfect choice for medical and dental applications. It has a soft and flexible texture like rubber and has a Shore A hardness of 30.
- Grey
- Biocompatible*
- Elastomeric
- Flexible
- Wear & Tear Resistant
Urethane Methacrylate
This digital light processing material’s mechanical properties surpass those of other materials. Its versatility makes it an excellent choice for various consumer products and industrial tooling applications. Its superior strength and durability make it ideal for use in applications where other materials may fail, and its unique properties make it an attractive option for manufacturers looking for a reliable and effective solution.
- Multiple Colors
- Biocompatible*
- Chemical Resistant
- High Strength
- Rigid
*Special processing may be required. Please notify us of any biocompatibility needs.
Design Recommendations
Designing digital light processing (DLP) parts requires careful consideration of several vital factors. The orientation of the part during printing can have a significant impact on the final product’s quality. In DLP printing, bottom-up curing of layers means that features that taper or overhang can negatively affect print quality. However, this can be mitigated by using supports or a strategically designed model. Since DLP printing can produce parts with fine details, it’s crucial to ensure that small features are adequately supported and printed at an appropriate resolution. Finally, it’s essential to consider the post-processing needs of the part, such as cleaning and finishing, and plan accordingly. By considering these factors, designers can create high-quality, functional parts using DLP printing technology.
| Feature | Measurement | |
|---|---|---|
|
|
Connecting & Moving Parts |
Rigid: 0.12 in Flexible: 0.04 in |
|
|
Escape Holes |
Rigid: 0.04 in Flexible: 0.04 in |
|
|
Embossing & Engraving |
0.02 in SIL 30 |
|
|
Holes & Openings |
0.002 in |
|
|
Horizontal Spans |
2x overhangs |
|
|
Minimum Features |
Rigid: 0.004 in Flexible: 0.04 in |
|
|
Pin Diameter |
Rigid: 0.004 in Flexible: 0.04 in |
|
|
Supports & Overhangs |
0.04 in EPU 40 &41 & SIL 30 0.08 in RPU 70 & 130, FPU 50, & EPX 82 0.12 in MPU 100 & UMA 90 |
|
|
Walls (Supported) |
0.06 in RPU 130, EPX 82, & SIL 30 0.04 in all other materials |
|
|
Walls (Unsupported) |
0.1 in |
| Feature | Measurement | |
|---|---|---|
|
|
Connecting & Moving Parts |
Rigid: 3 mm |
|
|
Escape Holes |
Rigid: 1 mm |
|
|
Embossing & Engraving |
0.5 mm SIL 30 |
|
|
Holes & Openings |
0.04 mm |
|
|
Horizontal Spans |
2x Overhangs |
|
|
Minimum Features |
Rigid: 0.1 mm |
|
|
Pin Diameter |
Rigid: 0.1 mm |
|
|
Supports & Overhangs |
1.0 mm EPU 40 & 41 & SIL 30 2.0 mm RPU 70 & 130, FPU 50, EPX 82 3.0 mm MPU 100 & UMA 90 |
|
|
Walls (Supported) |
1.5 mm RPU130, EPX 82, & Sil 30 1 mm all other materials |
|
|
Walls (Unsupported) |
2.5 mm |
Digital Light Processing Finishes
To ensure a high-quality final product, several steps must be taken when finishing and post-processing digital light processing (DLP) projects. Firstly, cleaning the printed object thoroughly is important to remove any excess resin. This can be accomplished by rinsing it with isopropyl alcohol and allowing it to air-dry. Secondly, the object may require curing using a UV light to harden the resin completely. This step can prevent the object from warping or cracking. Finally, sanding and painting may be necessary to achieve the desired finish. Sanding can help to smooth out rough surfaces or visible layer lines, while painting can add color and texture to the object. Overall, finishing and post-processing are essential components of DLP printing to ensure the final product looks great and functions well.
Why choose Prototek for your next digital light processing project?
Prototek is a leading provider of high-quality Digital Light processing services, specializing in prototyping and low-volume production. With over 30 years of manufacturing industry experience, Prototek offers a comprehensive range of Digital Light Processing solutions, including engineering support, rapid prototyping, tooling and mold making, and production manufacturing. Our skilled team of engineers and technicians utilize state-of-the-art technology and equipment, ensuring the highest standards of quality and precision. Prototek is committed to customer satisfaction and understands the importance of timely delivery. They offer competitive pricing, fast turnaround times, and exceptional customer service throughout the project process. Choose Prototek for your next Digital Light Processing project and experience first-hand their commitment to quality, innovation, and customer satisfaction.
