Carbon Digital Light Synthesis™ (Carbon DLS™) represents a groundbreaking advancement in resin-based 3D printing technology. Utilizing digital light projection, oxygen-permeable optics, and high-performance materials, Carbon DLSTM produces polymer parts with superior mechanical properties, high resolution, and an exceptional surface finish. This innovative process allows engineers and designers to accelerate their design cycles and explore new product possibilities by enabling the creation of consolidated parts, complex geometries, and software-tunable lattice structures. In this article, we will explore the key features, benefits, and applications of Carbon DLS, shedding light on why it’s becoming a game-changer in the additive manufacturing sector.
Table of Contents
The Carbon DLS Process
1. Digital Light Projection: Curing with UV Light
A: Building Platform, B: Resin. C: Oxygen Permeable Window; D: Dead Zone; E: Light Engine: Image Source: res.cloudinary.com
At the core of Carbon DLS™ is the pioneering Continuous Liquid Interface Production (CLIP) technology. CLIP employs a photochemical method to transform liquid resin into solid parts using ultraviolet (UV) light. The process involves projecting a sequence of UV images through an oxygen-permeable window into a reservoir filled with UV-curable resin. As each UV image is projected, the resin solidifies, and the build platform rises, forming the part layer by layer.
2. Oxygen-Permeable Optics: Enhancing Speed through the “Dead Zone”
Enhancing Speed through the “Dead Zone”: Image Source: res.cloudinary.com
A key feature of the CLIP process is the “dead zone”—a thin layer of uncured resin between the window and the part being printed. This layer allows light to pass through, curing the resin above it to form the solid part while preventing it from sticking to the window. The continuous flow of resin beneath the curing part maintains the liquid interface, avoiding the slow and forceful peeling process typical of many other resin-based printers.
3. Dual-Cure Materials: Strength Through Heat
Right: Cured Young’s Modulus and Left: Green Young’s Modulus
Traditional resin-based printing methods often result in parts that are weak and brittle. Carbon DLS™ addresses this issue with its dual-cure materials, which undergo a secondary thermal curing stage. After printing, parts are heated in an oven, triggering a secondary chemical reaction that strengthens the material. This results in parts with exceptional resolution and engineering-grade mechanical properties.
4. Achieving Consistent Isotropic Properties
Curing process: image source: res.cloudinary.com
Baking Process: Image Source: res.cloudinary.com
Unlike many 3D printing methods that produce parts with varying mechanical properties depending on their orientation, Carbon DLS™ creates parts with predictable isotropic properties. The parts are solid throughout, similar to injection-molded components, and exhibit consistent strength and behavior in all directions. This uniformity is achieved because of the continuous, non-layered nature of the printing process and the precise handling of the materials.
5. The Carbon Isotropic Advantage
The isotropic nature of Carbon DLS™ parts is a direct benefit of the dual-cure materials and the unique CLIP process. During printing, the “dead zone” ensures that the resin cures evenly along the z-axis. The subsequent thermal curing stage further enhances the isotropy by creating a molecular weave that strengthens the material in all directions.
6. Creating Fully Dense Parts
Powder bed Fusion: Image Source: res.cloudinary.com
Carbon DLS: Image Source: res.cloudinary.com
Carbon DLS™ stands out from powder-bed fusion technologies by producing fully dense parts. This characteristic ensures that the printed components are robust and reliable, making them suitable for end-use applications.
Why Choose Carbon DLS™?
1. Accelerated Product Development
Carbon DLS™ significantly speeds up the product development process. Designers can rapidly iterate on multiple designs, creating functional prototypes and moving seamlessly from prototyping to production. This efficiency is exemplified by brands like Adidas, Specialized, and Fizik, which have successfully scaled their production using Carbon DLS™ technology.
2. Design Freedom
The technology allows for complex designs without the constraints of traditional molding processes. Designers can create parts with undercuts, intricate geometry, and performance-oriented lattice structures without compromising manufacturability. This flexibility enables the creation of highly optimized components tailored to specific applications.
3. Customization and Aesthetics
Carbon DLS™ offers extensive customization options. Without the need for tooling, each unit can be unique, allowing for personalized designs and products tailored to individual preferences. Additionally, the technology supports surface textures and finishes that enhance the visual and tactile qualities of the parts.
Material Options for Carbon DLS™
Carbon DLS™ supports a range of materials, including:
- Rigid Plastics: CE 221, UMA 90, DPR 10, EPX 82, FPU 50, RPU 70
- Rubber-like Plastics: EPU 40, SIL 30
These materials cater to various applications, from durable, high-strength parts to flexible, impact-resistant components.
Advantages of Carbon DLS™ Technology
1. Complex Designs with Ease
Carbon DLS™ excels in producing complex designs due to its resin-based approach, which allows for intricate internal features and undercuts that are challenging to achieve with other methods like powder bed fusion. The technology’s ability to create lattice structures further enhances its design capabilities.
2. Enhanced Mechanical Properties
Unlike other resin-based printing processes such as SLA or PolyJet, Carbon DLS™ incorporates a secondary thermal curing stage that significantly enhances the strength of printed parts. This continuous process provides isotropic properties, ensuring consistent strength regardless of orientation.
3. High-Quality Surface Finish
The use of resin in Carbon DLS™ results in a glass-like surface finish, which surpasses the quality of parts produced by powder-based methods or filament-based processes. This smooth finish, combined with the high resolution of the technology, makes it ideal for both prototypes and end-use parts.
4. Precision and Detail
Carbon DLS™ achieves a high level of precision with layer thicknesses as fine as 0.001mm. This capability allows for the creation of small, detailed parts as well as larger components, maintaining tight tolerances and high-definition features.
5. Minimized Material Waste
The CLIP process minimizes material waste by allowing the resin to be reused after printing. This efficiency contrasts with the higher waste levels associated with powder-based or filament-based 3D printing technologies.
6. Bio-Compatibility and Food Safety
Certain resins used in Carbon DLS™, such as SIL 30 and RPU 70, are bio-compatible, making the technology suitable for medical implants and food containers. This advantage sets Carbon DLS™ apart from other 3D printing technologies that lack similar material options.
7. Flexible Printing Capabilities
It offers flexible printing options with resins that provide rubber-like properties, making them suitable for functional parts used in real-world applications.
Considerations for Carbon DLS™
1. Cost
Carbon DLS™ is one of the more expensive 3D printing technologies available. The cost of production, including setup and material expenses, can be higher compared to methods like MJF or FDM. This cost factor may impact the affordability of multiple prototypes or trial iterations.
2. Material Limitations
The selection of materials for Carbon DLS™ is currently limited, with only a few options available. Additionally, while post-processing can add color, it increases the overall cost.
3. Xometry’s Carbon DLS™ Services
Xometry Europe offers Carbon DLS™ services for on-demand 3D printing projects. With a network of over 2,000 partners across Europe, Xometry provides quick turnaround times, delivering Carbon DLS™ parts in as little as five days. Customers can upload CAD files to Xometry’s Instant Quoting Engine for instant quotes and various manufacturing options.
Key Insights About Digital Light Synthesis
1. Enhanced Smoothness and Durability
Digital Light Synthesis™ improves upon traditional 3D printing by eliminating layer lines, resulting in smoother surfaces. The secondary heat-curing process further enhances the mechanical properties, producing high-resolution, engineering-grade parts.
2. Speed to Market
The ability to prototype, test, and produce in one process accelerates the time to market. This efficiency reduces costs and allows for faster delivery of products to customers.
3. Material Availability
Carbon DLS™ offers a range of materials, including RPU, FPU, EPU, CE, EPX, UMA, and dental resins, each with unique properties suited to different applications.
4. NASA Seeker Robot Collaboration
Carbon’s technology played a crucial role in NASA’s Seeker robot project, demonstrating its capability for rapid, cost-effective production of high-performance components. The collaboration highlighted the potential of additive manufacturing in space applications.
5. The Technology House and Carbon DLS™
The Technology House (TTH) has been a leading partner in utilizing Carbon’s additive technology. With advanced machines like the M3 Max, TTH offers high-quality, reliable manufacturing solutions for various industries, showcasing the benefits of Carbon DLS™.
SelfCAD: Best 3D Printing Software
SelfCAD is a user-friendly 3D design and printing software that doesn’t require extensive training, making it accessible to more than just professional engineers. Designed by an innovative team, SelfCAD offers an intuitive interface that simplifies the 3D design process, especially for beginners.
Despite its ease of use, the software includes advanced tools for 3d modeling, sculpting, and 3D printing preparation, ensuring a realistic and unrestricted creative experience. It allows users to modify existing designs or create complex objects without needing additional software. For example, you can import an STL file and color it as shown below.
With a low entry cost, SelfCAD is accessible to everyone, including professionals, hobbyists, and students. As a browser-based platform, it enables users to model, sculpt, slice, and print online without long learning curves or high costs while also providing cloud storage for easy sharing and collaboration.
Mastering Complexity and Speed with Carbon DLS Technology
Carbon Digital Light Synthesis™ offers significant advantages in 3D printing, including rapid prototyping, high-quality finishes, and the ability to create complex designs. While it comes with considerations such as cost and material limitations, its unique capabilities make it a valuable technology for advanced manufacturing applications.
