2.

LIQUID BASED SYSTEMS

Content:
Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle,
photopolymers, photo polymerization, layering technology, laser and laser scanning, Applications,
Advantages and Disadvantages, Case studies. Polyjet System (PJS): Model sand specifications,
Process, working principle, Applications, Advantages and Disadvantages, Case studies, Perfactory
(DLP)

Principle: Parts are built from photo-curable liquid resin that cures when exposed to
laser beam (photo-polymerization process) which scans across the surface of resin.

Stereolithography (SLA) Technology (1).mp4

.
Chuck Hull, Co-Founder, 3D Systems, founded At 74 in 1986
 Fig. Application of SLA: rigid resin for stiffness and precision
Photopolymers (1960): ….Acrylate resins, Epoxy resin, hybrid resin.
Most SL resins commercially available are epoxides with some acrylate content.

Applications: Paper coating, ink jet Printing, Dentistry

2.1 STEREO LITHOGRAPHY APPARATUS (SLA) / VP

Stereolithography (SLA) 3D Printing Process by 3D Systems.mp4

[[Link]
SLA is the most widely used RP-technology. Introduced in 1988 by 3D Systems Inc.

Fig. SLA process apparatus

Process: The vat is filled with photo-curable liquid resin and elevator platform is set
below liquid resin.

Load 3d cad model file in to system. .STL file. Develop slice file for component model
and supports into series of cross sections- from 0.025 to 0.500 mm thickness.

Optical scanning system: directs and focus laser beam. Depth more than one layer
thickness. The first layer gets solidified.

Radiations used: Gamma rays, X-rays, EB, UV, and in some cases visible light.
Helium–cadmium (HeCd) laser, wavelength of 325 nm. Solid-state lasers Nd-YVO4.
Elevator platform is drop enough again to cover solid polymer. Sweeping wiper blade
does recoating & control of next layer of liquid resign. Again laser draws next layer…
Main components of SLA system are a Control computer,
Control panel, a Laser, Optical system and a Process chamber.

Software: 3D Lightyear, OS: Windows NT

Photo- polymers-solidified when exposed to Electro-Magnetic radiation includes

wavelengths in Gamma ray, X-ray, UV rays and EB.
In SLA photopolymers are curable in UV range. These polymers are formulated
from photo initiators and reactive liquid monomers.
Thermoplastic polymers that are typically injection molded have a linear or branched
molecular structure that allows them to melt and solidify repeatedly.
Thermosetting polymers: Ceramic resin, Standard resin, Castable resin and Clear resin

In contrast, VP photopolymers (c) are cross-linked and, as a result, do not melt and
exhibit much less creep and stress relaxation. As shown in fig. of polymer structures.

Slow photo speed and brittleness of the cured parts, Acrylate added to epoxy resins.
Photopolymers: Some may contain fillers and other chemical modifiers to meet
specified chemical and mechanical properties.
Photo-Polymerization: It is process of linking of small molecules (monomers) into
chain like larger molecules (polymers).

Polymerization is initiated by photo-chemical process, with starting point as

induction of energy from appropriate source.

A catalyst is required for polymerization to takes place at reasonable rate. The

catalyst is usually a free radical is generated thermally or photo-chemically.

Plastics are made out of long carbon chains. The shorter the chain, the less solid or
viscous the plastic.

Resin is a plastic composed of short(er) carbon chains—from 1 carbon to a few

thousand carbons. It has all of the components of the final plastic, but hasn’t been
fully polymerized yet.

When the resin is exposed to UV light, the chains join together to create much longer,
therefore stiffer chains. When enough chains have reacted, the result is a solid part.
Polymerization of VP monomers is an exothermic reaction, with heat of reaction
around 85 kJ/mol. for an example acrylate monomer.
On an average, for every two photons (from the laser), one radical will be produced.
That radical can easily lead to the polymerization of over 1,000 monomers, as shown
in the intermediate steps of the process, called propagation.
In general, longer polymer molecules are preferred, yielding higher molecular
weights. This indicates a more complete reaction.
In Fig. 4.4, the P–I term indicates a Photoinitiator, the_I● symbol is a free radical,
and M in a monomer.
Form lab Printer: Form2
Process Modeling:
Software: convert 3d model into .STL and reproduce it in laser scanning system.

Layer thickness is controlled by precision elevation mechanism. It corresponds to

slice thickness and cured thickness of resin.

By application of the Beer–Lambert law, the theoretical relationship between resin

characteristics and exposure can be developed, used to specify laser scan speeds.

Irradiance, the radiant power of the laser per unit area, H(x, y, z). As the laser scans
a line, the radiant power is distributed over a finite area.

Equation for a Gaussian laser beam is given here as

where, Dp = Penetration depth, z = Dp; we get that the irradiance

at a depth Dp is about 37 % (e-1 = .36788) of the irradiance at the resin surface.

Lw = Cured line width, Cd = Cured depth,

W0 = radius of laser beam [mm], Dp = Depth of laser penetration
At the resin surface and in the center of the scan line:

E= Exposure, function of spatial coordinates [energy/unit area] [mJ /mm2]

Ec= Critical exposure = exposure at which resin solidification starts to occur.
Emax = peak exposure of laser shining on the resin surface (center of laser spot).

Where, PL = laser power, Vs = laser scan velocity

And Cure depth (Cd) is function of,

Since Dp and Ec are purely resin parameters, the slope and intercept of the
Working curve are independent of laser power.
Strength and weakness of SLA

Strength of SLA Limitations

1. Round the clock operation: 1. Required support structure: for

continuous and unattended. overhang and designed with part.

2. Build volume; range is wide 2. Required post processing: remove,

(250 x 250 x 250)mm to finish support and extra material.
(737 x 635 x 533) mm.
3. Good accuracy
4. Good surface finish. 3. Post curing is needed.
5. Wide range of materials for
specific application.

Characteristics of Resins and Plastics:

Different resins: Different backbones and side groups:

Combinations of long and short monomers,
oligomers, photo initiators, and additives.

Unique freedom to create various formulations:

with a wide range of Optical, Mechanical, and Thermal properties.
Clear to Opaque and Colored, Flexible to Rigid, Tough to Heat resistant.

Composition of Photopolymer Resin

Component Role
Monomers and
The core of the resin; carbon chains that will make up the solid parts.
Oligomers
Photo initiator Molecules that react when exposed to UV light, initiating the reaction.
Additives Visual and functional supplements, such as pigments or dyes.
Anisotropy: Due to layering technique in many cases material properties vary to
some degree according to the direction in the material in which they are measured.

During SLA, the components of the resin form covalent bonds. Provides high degrees
of lateral strength, but the polymerization reaction is not driven to completion.

Rather, the print process is modulated in a way that keeps the layer in a semi-reacted
state called the “green state.”

Post-Curing: Adding a post-cure chamber to the printing process finalizes the

polymerization process and stabilizes the mechanical properties.

This enables parts to reach the highest possible strength and become more stable.
e. g. functional resins for engineering, dentistry, and jewelry.

Thermoplastics: can be melted into a liquid state and cooled multiple times to form.
Thermoset: no change in solid state after curing (heating), as of chemical bonding.

WEAVE Pattern:

Prior to the development of WEAVE, scan patterns were largely an ad hoc

development. As a result, post-cure curl distortion was the major accuracy problem.

The WEAVE style consists of two sets of parallel laser scans:

• First, parallel to the x-axis, spaced 1 mil (1 mil= 0.001 in. = 0.0254 mm, a standard
unit of measure in SL) apart, with a cure depth of 1 mil less than the layer thickness.

• Second, parallel to the y-axis, spaced 1 mil apart, again with a cure depth of 1 mil
less than the layer thickness.
On the first pass, a certain cure depth is achieved, Cd1, based on an amount of
exposure, Emax1. On the second pass, the same amount of exposure is provided and
the cure depth increases to Cd2.

The incremental cure depth caused by the second pass is just ln (2) Dp, or about
0.6931Dp. This distance is always greater than 1 mil. Fig. WEAVE scan pattern
 Digital Light Processing (DLP)

 Desktop DLP 3D printers are built around a resin tank with transparent bottom
and a build platform that descends into a resin tank. Create parts upside down.
 Light source: DLP 3D printers use a digital projector screen to flash an image
of a layer across the entire platform, curing all points simultaneously.
 The light is reflected on a Digital Micro-mirror Device (DMD), a dynamic
mask consisting of microscopic-size mirrors laid out in a matrix on a
semiconductor chip. (Bottom up approach)
 Rapidly toggling these tiny mirrors between lenses that direct the light towards
the bottom of the liquid resin tank or a heat sink defines coordinates-cures.
 Because the projector is a digital screen, the image of each layer is composed
of square pixels, resulting in a three-dimensional layer formed from small
rectangular cubes called voxels.
Printer: Form 3B
Technology Low Force Stereolithography (LFS)™
XY Resolutionᵃ 25 microns

Laser Spot Size 85 microns

Laser Power One 250 mW laser

Build Volume (W x D x H) 14.5 × 14.5 × 18.5 cm

Layer Thicknessᵇ 25 – 300 microns

Resin Fill System Automated

Biocompatible Materials Yes

Supports Auto-Generated Light-Touch Removal

Internal Temperature Auto-heats to 35 °C

Temperature Control Air-heated print chamber

Operating Environment 18 – 28 °C

Power Requirements 100–240 VAC, 2.5 A, 50/60 Hz, 220 W

Laser Specifications 1 Light Processing Unit EN 60825-1:2007 certified

Class 1 Laser Product, 405 nm wavelength

250 mW power, 85 micron (0.0033 in) laser spot

Connectivity Wi-Fi (2.4, 5 GHz), Ethernet (1000 Mbit), USB 2.0

Printer Control 5.5" interactive touchscreen, 1280 × 720 resolution

Alerts Touchscreen alerts, SMS/email via Dashboard

Two LED status indicators, Speaker for audio alerts
System Requirements Windows 7 (64-bit) and up, 4 GB RAM

File Types STL and OBJ file input, FORM file output
PreForm Print Setup One-Click Print
Features Adaptive layer thickness for faster printing with fine details
Remote Print, Auto-orient for optimal print position
Auto-mesh repair, Auto-generation of supports, Rotate,
Scale, duplicate, and mirror
Layer slicer for path inspection

Introducing The Form 3B_ Optimized For Dental.mp4

Process Steps: i. Scan ii. Design iii. Print

iv. Prepare v. Thermoform vi. Polish and Finish

Crown and Bridge models, Clear aligner models, Surgical guides, Splints and
Occlusal guards.
Case Study: Silicon Mould by SLA / DLP
SLA Materials by Application
Standard resins provide high resolution, fine features, and a smooth surface finish
right out of the printer.

While post-curing is recommended, it’s not required for all uses, making these resins
ideal for rapid prototyping, product development, and general modeling applications.

Properties: High details, good surface finish and no post curing

ZOD Impact Strength [J/m], Elongation [%], Tensile modulus [GPa], Flexural modulus [GPa]

Fig. Standard resin types

Applications of SLA: Range of applications includes
i. Models for conceptualization and presentation

Fig. Small highly intricate models, Watershed™ resin.

The Viper in Ultra Hi-res mode utilizes the lasers extremely small spot size of just
0.075mm to produce precise, crisp detail on even the most intricate complex parts.

The smallest possible detail is also much finer on SLA, given 140 micron laser spot
size on the Form 2, in comparison with 350 microns on industrial SLS printers, and
250–800 micron nozzles on FDM machines. ([Link]

ii. Prototypes for design, analysis, verification and functional testing

iii. Parts for prototype tooling and production tooling of low volume.

Fixture for Vacuum Cleaner Component

iv. Pattern for investment casting, sand casting.

 v. Patterns for Silicon molding

Tools for Inj. Moulding

Injection Molding with 3D Printing - How It's Used.mp4

For fixture and tooling design.

A part being clamped between soft jaws inserts. A press fit bushing in a drill jig (Tough resin)
Designing for SLA / DLP
Vat polymerization techniques (SLA/DLP) use a light source to cure a photopolymer
resin. It is best suited for parts with a high level of accuracy and a smooth surface.

Most design recommendations for SLA/DLP center around support location and the
effect support has on the surface finish.

i. Support structures and Part orientation

 Both bottom up and top down SLA/DLP printers require support structures.
Support secures the model to the build platform, prevents warping and helps to
reinforce overhangs and other complex features.
 Most SLA/DLP slicing programs allow for auto-generation of support based
on the design of a part.

 SLA/DLP technologies can only print support with main build material. This
means that the support must be manually cut or broken away from final part.
 To assist with removal, support material is printed as thin, tree-like structures
that narrow to a point where they contact the print (Figure 12.1).
o The nature of SLA/DLP support means that marks or stubs can be present on
the surface after removal. Then need to be sanded for smooth surface.
o Hence, designer needs to understand the support requirements for a part and
how the part is orientated, to ensure surfaces are not in contact with support if
their appearance is important.
o This is particularly relevant for parts like Visual prototypes, Injection molds,
Dental applications and Hearings aids, where a smooth surface is essential.
o Complex details in inaccessible areas will make removal of support material
difficult and increase the likelihood of damage to the model occurring.
o Bottom up and top down printer configurations requires different approaches.

Top down support structures

o Top down printers have very few design restrictions.
o Parts are able to be orientated in any direction with a flat alignment- optimal.

Bottom up printers: require more complex orientation and sup. structures.

o In a peeling stage, risk of the print remaining stuck to the build plate can-fail.
o Part orientation plays an important role in ensuring this does not occur.
Materials with a Shore hardness of less than 70A are not suitable to print with.
o Guidelines that help to govern how a part should be orientated:
1. Parts should be oriented so the longest axis is parallel with the front m/c.
2. Orientated in an attempt to reduce the cross sectional area of each layer to
lower the forces that the part is subjected to during the peeling stages.
3. Enclosed cavities should not be orientated so that they face the resin tank
(see Hollow Sections).
4. So that they are able to build off previous layers. This reduces the
dependence on support material (- small or intricate features safe removal).
o Software: option to automatically orientate parts and generate support.
Rotate the part 60° around the y-axis 3. Rotate the part 30° around z-axis.
ii. Hollow sections
o Hollow designs are a popular choice for SLA/DLP parts as they decrease
material use and lower print costs.
o When printing hollow sections using SLA, it is important to check that
hollow designs do not require internal support as it is difficult to remove.
o The use of hollow sections can result in some issues?
SLA/DLP designs must have escape holes included (size?).
o The position of escape holes is as important as the size. As a good rule of
thumb, escape holes should be positioned opposite one another.
o Holes should also be placed in the lowest and highest part of a design or
in corners where drainage of resin may be difficult.
iii. SLA/DLP Design table
QS:
Q1. Justify “VP is a good process to use to fabricate patterns for investment
casting of metal parts”.
Q2. What are different photopolymers and its applications?
Q3. Brief process of photo polymerization.
Q4. Draw a sketch representing VP SLA.

Q6.
Q7. How DOD printer works? Where it is applied?
Q8. Draw a sketch of polyjet printer.
Q9. Explain working and features of polyjet printer.
Q10. Enlist strength and limitations of polyjet printer.
Q11. Brief specific applications of polyjet technology.
 2.2 POLYJET SYSTEM

Introduction
Object Geometries ltd., Israel 1998. Inkjet based technology.
High quality and fine details of part. Widely used in world. PJ > 40 patents.

Applications:
o Ideal PolyJet applications include master patterns for molds;
o Show models; detailed prototypes; Form, fit, and feel models,
o Low volume injection mold cavities; and moving assemblies.

What is PolyJet 3D Printing Technology - Smooth, Multi-Material Additive Manufacturing.mp4

Fig. Master pattern for mould

Web resources: [Link]; [Link] Fig. Different polyjet parts
Introduction to PolyJet (PJ) / Material Jetting (MJ)

Polyjet (as PJ) 3D printers are a subclass of the Material Extruding / Jetting 3D
Printers category.

Material jetting: that jets a liquid (the build material) from a print head, which is
then solidified by UV light.

In most material jetting processes, the build material is a photopolymer.

PolyJet 3D printers deliver high quality, multi-material printing and multi-colour.

N Principle: Polyjet printer jet out tiny droplets of photopolymer liquid on to the
build platform, which is then cured instantly by ultraviolet light, similar to inkjet
printing. UV light is integrated with jetting head.

N Parts are built from liquid photopolymer, layer by layer, by polymerization.

Jetting head moves in X and Y direction, as per slice file. Z -by elevator

N Both part and support material gets cured by UV rays.

o Once a layer is complete, the build platform drops along the Z axis….
o Nontoxic support material can be removed easily by water jet.
o Material cartridges - connected to the nozzles. Layer ht. as low as 16 µm

PolyJet Technology.mp4
 Fig. Schematic of PolyJet process

 Process: Jetting head move along x axis, print first layer, then along y axis and
move on to x axis, print next layer. Deposit material in a rapid, line wise fashion
 During printing, Part and Support materials are different, it’s released for that
layer. Support and part material is printed simultaneously.
 Support: with dissolvable material.
Every layer material is cured immediately by UV light, as head moves along.
 First 2D cross section is printed, then build trey will drop down by Lt = 16 µm.
One of accurate form of 3d printing process results in smooth surfaces.
 Post Processing: Part finished by Water jet.
Print multiple parts in a single line with no effect on build speed/ faster.
Drop on Demand (DOD) Printers have 2 print jets; one to deposit the build
materials (typically a wax-like material) and another for dissolvable support material.

DOD printers employ a fly-cutter that skims the build area after each layer: Flatness.
Technology is typically used to produce “wax-like” patterns for lost-wax
casting/investment casting and mold making applications.

PolyJet Printers – Build Materials: Thermoset photopolymer resins.

 Materials with low viscosity that can successfully be jetted in droplet form.
e. g. Clear, rubberlike, Biocompatible photopolymers, and Tough.
 Most resins are heated up (from 30 - 60°C depending on the printer and
material) as they are printed.
 Material Jetting always requires 2 different resins.
 Because Material Jetting uses hundreds of tiny nozzles to jet the build material
it is possible to produce multi-material/Color prints.
 The resin cartridges used in Material Jetting machines are generally proprietary
and cost around $300 - $1000 per kg.
Designing for Material Jetting (MJ)
o Material Jetting is one of the most accurate 3D printing technologies,
producing high detail parts with a very smooth surface.
o Full color, or Multi-material parts,
o Regularly use: Visual Prototypes.

o The lack of heat present during the Material Jetting process as well as the use
of dissolvable support material allows for a high level of design freedom.
o Most design recommendations for Material Jetting center around allowing
adequate room for the removal of support material.
 i. Support structures and part orientation
 Material Jetting prints support from a secondary dissolvable wax-like
material that is removed after the print is complete.
 The need to manually remove support material places limitations on design.
 Any fully enclosed cavities will be filled completely with support material
that cannot be removed.

For other walls also, minimum thickness = 1.0 mm

 In addition, long, narrow cavities or small holes are very difficult to clean.
Because of this, any holes or channels should be > 0.5 mm in width.
 Escape holes generally do not assist with the removal of support (its solid).

Embossed and engraved details with 0.5 mm below or above surface.

 Manual support removal with small tools / pressurised water.
If stronger features are required, consider using the glossy finish (instead of matte) option.
 This allows for better layer bonding (3 layers stepwise), reduces porosity, and
also results in parts with homogeneous properties, regardless of orientation.
 The high cost of Material Jetting support material often sees designs orientated
to limit support usage

ii. Full Color printing

 One advantage of Material Jetting is the ability to produce multi-color prints
that accurately represent end products.
 Full color models can be exported as three file types; STL, OBJ and VRML
STL is best suited for designs that include discrete colored sections,
while OBJ or VRML: designs with opaque color or textures that blend.
 OBJ files can be accompanied by a MTL (which references the materials
and colors used in a design.
 So as colors do not bleed into each other, a mini. shell thickness = 2 mm.
Achieving vibrant color can also be accomplished by printing a part in
matte, ensuring a uniform finish across the print, and smooth finishing
iii. Multi-material integration
 MJ: Only technology that is capable of printing multi-material parts at once.
 Functionality:
i. Mixed tray: It produces separate parts from different materials on the same
build platform. For example, a flexible rubber part and rigid part.

This removes the need to change materials between prints, improving efficiency.
ii. Digital materials: combining two or three resins in specific concentrations and
microstructures to create a composite material.
iii. Mixed parts: multiple materials for separate section.
As n example e.g. direct assembly, high speed. Realistic designs.

Multi-material Design:
 Mixed part prints: design with discrete bodies or shells,
assigning each body a different material.
 In CAD: Each Part Model and material.
bought in an Assembly (Figure 14.3)
 Export Assembly
(with option of each component as a separate STL file.)
Assign print material to each individual part.
 Work with an assembly of parts with zero clearance
BOM with design.
Fig. Injection mould by PJP Fig. Injuction molded part
Strengths of PJS / Material jetting:
1. High quality: layer thickness (LT) as thin as 16 µm.
Homogeneous part.
2. High accuracy: precise jetting, fine details and thin walls (600 µm or less)
3. Fast process speed: no draining, stripping, polishing. Easy wash of support.
4. Smooth surface finish: model build gives smooth surface finish, fine details.
5. Material range is wide: Tough acrylic-based photo polymer to PP.
–like plastic (duruswhite) to rubber like Tango material.
6. Color, Easy cartridge: material is easy to replace / colors.
7. SHR technology: Machine head and Nozzle replacement
8. Safe and clean process: User, Material and Noise

Limitations:
1. Post Processing: Support wash by water jet.
Thin, small and delicate parts are crucial.
2. Material Wastage: support material reuse?
3. Mechanical properties: low and brittle.
4. Printing Cost: expensive methods of 3D printing.
(High cost of the material and solid support)
Process Characteristics
1. Printer Parameters:
 Jet droplet size (jet diameter) and layer height influence.
Surface finish and minimum feature size of a part.
 Capability of LH and smooth surfaces.
 Maintenance of the print head: to restrict clogging or blocking due to the
small jet diameters. Jets cleaned or notified.
 Resin heating to an optimal temperature (@ 30 - 60°C) to control the
viscosity. Parameters and resin material.
2. Support Structures:
 Parts printing material: build and dissolvable support.
 Support is dissolved and easily removed with light agitation.
 Support design. Orient. flexible.

+
3. Matt(M) and Glossy(G):
 Material Jetting print: either matte or glossy.
 The Matte: setting will add a thin coating of support across the entire part
surface. It is more uniform and accurate finish. Soft surface.
 The Glossy: only use support material where required (overhangs, drafts).
A smooth and shiny surface finish on areas with no support.
A reduction in material usage.
4. Dimensional Accuracy
 Most accurate form of 3D printing process.
 Losing some accuracy: as part size increases due to photopolymers
shrinking as they cure.
[Link] run injuction mould printed from Digital ABS, used to produce batch of sensor housing.

Fig. P-Jetted part, Tango black (Rubber like).

Fig. Stratasys Object 500 Connex 1
[Link]
Stereolithography PolyJet

UV Curable
UV Curable

Support Removal: Hand sanding, light bead blasting, Water blasting, by hand,
Material is same. Different material.
Materials: rigid clear, grey and white opaque all colors, opaque and transparent
rigid and flexible

Excellent Resolution at 0.015 mm

Resolution: Good at 0.125-0.050 mm

Small Detailed Prototypes and

Ideal Size of parts: Large Models and master Patterns Patterns

SL parts are not built fully cured in order to drain out excess
resin, they require additional curing in a UV oven. PolyJet parts are built fully cured

Finish: Less smooth surface of build part. smoother surface right off the
build

Functional prototypes and rigid

Application: for model presentation
parts
Ability to print mostly hollow parts using an interior
Honeycomb structure.

Key appli. : Wax patterns for investment casting

Multi-material (or hybrid)
multi-material (or hybrid) printing.
printing.
Applications of PJS:

Material jetting regularly being used for realistic, non-functional, prototypes that
closely represent end parts.

1. Engg. Design: Analysis and testing

2. Concept models and presentation: Sales and market research
Verification of Injuction mold design
3. Tooling and casting: Patterns of investment casting, Direct tooling, Mfg. of
plastic parts (tool free); in creation of Silicon moulds. VLT mould (alternative
to rubber mould), Vacuum forming. Low run injection moulds.
4. Medical models / imaging
Diagnostic, surgical operation and planning.
Custom prosthesis design (dental, limbs, valves)
Prosthesis devices (hearing aids, Eyeglasses, orthopedic shoes, bone plates)

5. Jewelry industry: Concept design, proofing and fitting

Jewelry model presentation. Market research
6. Packing: Formers of vacuum forming made from ABS polymer.
Mould is developed from HIPs sheet. (Less expensive and short time process).

What is Vacuum Forming .mp4

 2.4 SOLID GROUND CURING
Introduction
SGC system produced by Cubital limited, Israel.
Wide range models and options for models.
Use different resins: liquid photosensitive resin, cured resin,
Water soluble wax: as support material
Solid toner: for developing erasable image on glass (mask).

It is process where 3D component is build using glass mask, layer by layer on photo
sensitive laser using UV rays with wax filling and milling of component.

SGC steps for each layer:

1. Mask preparation
2. Apply liquid photopolymer resin on build platform
3. Mask positioning and its exposure to UV light
4. Remove uncured resin by vacuum
5. Wax filling
6. Milling for flatness and thickness
0

videoplayback.mp4
Principle
Part of any complex geometry is produced without tools, dies or moulds by SGC.
i. Parts are built by layer by layer from liquid photo polymer resin, when
exposed to UV (high power) light by photo polymerization. Where image of
layer is generated by mask illumination.(not by optical scanning by laser).
ii. Layer Mask is printed on glass mask plate, by nonimpact inographic print.
Image is formed by depositing black powder (toner) on glass plate, which
adheres electrostatically. For next layer mask is made on same plate and used.
iii. Multiple parts can be built in parallel.
iv. Layers are created thicker than desired.
v. Process is self-supporting vi. Software: Cubital RP software.
Facts about SGC
Time to produce part by SGC claims to be eight times fast than other systems.
Sequence for each layer takes @ 60-90 seconds.
Solid cubic form of prototype is consist of solid polymer and wax.
Wax provides support for overhangs, can be melted further.

Advantages of SGC system:

i. No Post curing of build component.
ii. High structural strength and stability. As elimination of post curing, avoids
internal stress and warping.
iii. Part complexity does not affect speed, but volume does.
iv. Intermediate stopping and start of other job and again first.
v. Supports are not required. (wax does it.)

vi. Many parts can run (build) at a time.

vii. Layer can be milled off, if found error.
viii. Minimum shrinkage effect, as complete layer gets cured.

Limitations:
i. Overexposure of resin increase its viscosity, may result unusable.
ii. Light sealed chamber and toxic materials are used.
iii. Machine size is very large.
iv. System is noisy and high maintenance and supervision is required.
v. Removal of wax after production is essential /wax stuck.
vi. Few materials are availed.
Applications:
i. Product Design, testing, analysis and presentation
ii. Casting applications
Patterns for investment and sand casting.

iii. Tooling: Silicon rubber tooling, epoxy tooling, spray metal tooling.
iv. Medical imaging Diagnostic, surgical planning, Custom prosthesis design.
Digital Light Processing (DLP)

N Type of vat polymerization.

N Vat of liquid polymer is exposed to UV light in safe conditions.

N An in-built projector that sits under the resin container projects slices.

N The light source is a specially developed digital light projector screen.

An LED screen. Small Micro mirrors, high Resolution

N 2D image that is projected is composed of pixels. When translated into

three dimensions, they become voxels.

Test driving the Photon UV Resin DLP 3D Printer from Anycubic.mp4

Special features of DLP Printing machine.
 Light source: stationary
Control over intensity of UVL
Replacement is simplified and low cost
 Curing of resin: layer wise
 Printing speed: significantly higher, slight low accuracy
 Suitability: to build one-off small and intricate part
e. g. Jewelry designs

Flashforge Hunter
Case studies on DLP:
[Link]
[Link]

Case study on SLA:

[Link]
manufacturing
 Case study: Polyjet Technology

PolyJet- 3D Printing.mp4

Ref. [Link]

Retooling the Engine Using 3D Printing

Volvo Construction Equipment (VCE).
Recently, Volvo engineers designed a new water pump housing for their AG30 and
A25G articulated haulers.

Used Simulation to design the internal flow of passages in the housing.

Challenge: to develop a Prototype,
In the past, the cost of tooling, would be around $9,090,
with the actual part costing approximately $909.

Lead time: at least 20 weeks

Improving Big Engines
Objective: To cut development costs.
While also reducing the lead time from 36 months to 24 months.
ERs looked to AM as a benchmark, with functional testing.
The requirements for a water pump housing prototype:
It must be able to resist the high pressure and heat of the engine compartment.
VCE, used a Stratasys® Objet Eden260V™ 3D Printer and

PolyJet 3D Printing Technology from its Shippensburg, Pennsylvania site.

Material Full Cure® 720, to 3D print the housing piece.
Post processing: mounted nine threaded inserts into the printed part.
Sealed the housing with epoxy resin and hardener.
Attachment of the jacket to a water pump and
then mounted the pump to an A30G.

To evaluate: water pressure and flow measurements from both the water pump.
Testing: the newly designed housing had passed the test.
Completed the test much sooner and more cost-effective way.

JAN 17, 2015 - [Link]

A New Way of Silicone Molding with 3D Printing Technology

Silicone Molding with a 3D Printer.mp4

Silicone molding (also known as RTV molding).

Silicone (RTV) molding:

Solution for low-volume prod. of plastic parts.

Applications: medical, aerospace, and electronics.

Challenge: Design and develop Pattern and Mould

Process Features: Develop pattern with PolyJet-based AMT

N Create the silicone mold patterns from a few weeks to a few hours.
High resolution capability of Polyjet.

N Even extremely complex or intricate patterns do not add time or costs.

Patterns have smooth surfaces and are mold-ready,

N Incorporate tight tolerances and fine details.

N Mold rubbers: natural latex, polyurethane, epoxy and silicone.

Silicone Molding with a 3D Printer.mp4

Making it attractive for casting materials:

Cement, Vinyl, Wax, Plaster,

Low-melt metals,

Urethane resins, Epoxy resins, and Polyester resins.