The Advantages, Limitations, and Applications of DLP 3D Printing

Digital Light Projection (DLP) 3D printing is a powerful additive manufacturing method that excels in creating highly detailed parts with exceptional accuracy. Here’s an overview of its strengths, drawbacks, and most common applications.

Pros of DLP 3D Printing

High Accuracy

DLP technology uses a digital light projection to cure photopolymer resin, achieving exceptional detail and accuracy. This makes it ideal for producing intricate designs that require tight tolerances.

Speed

By curing an entire layer at once, DLP is faster than processes like SLA, making it ideal for time-sensitive projects. This efficiency allows for quicker turnaround times, even for complex geometries.

Smooth Surface Finish

Parts produced using DLP have a fine surface finish, reducing the need for extensive post-processing. This characteristic is particularly valuable for applications where aesthetics or fit are critical.

Material Properties

DLP offers a range of resin materials with a focus on end-use, including flexible, biocompatible, and high-temperature resistant options. These materials cater to specialised industries such as healthcare and electronics.

As the materials have been developed with end-use in mind you will find the data sheets are far more in depth as more testing has been completed to ensure materials will stand the test of time.

We stock a range of materials to meet most requirements, including a high temp (up to 300oC) material; we can also order specialist materials for projects with different requirements.

Cons of DLP 3D Printing

Build Volume

The process is typically limited to smaller build sizes compared to other 3D printing technologies. This constraint can be a challenge for projects requiring larger components.

Our DLP 3D Printer has a build envelope of 124.8 x 70.2 x 196 mm (XYZ). Horizontal resolution is 65 microns, and layer thickness is from 10 to 100 microns, depending on the material.

Wall Thickness 

Although larger wall thicknesses can be achieved it is best avoided with this technology. This is because the parts print upside down hanging from supports on the platform and is also cured through a clear membrane inside the vat of material so it is best to avoid large dense sections to minimise surface tension from the membrane and gravity from dense prints.

“If a part is designed with injection moulding in mind, it will be suited for this process.” – Justin, Managing Director.

Support Structures

Supports are required with DLP and can have a larger impact in comparison to SLA as extra strength is needed due to the reasons mentioned in the “wall thickness” section above. We will verify suitability for the process with your parts.

Applications of DLP 3D Printing

Dental and Medical

DLP is widely used for dental models, surgical guides, and prosthetics due to its precision and material options. These applications benefit from the technology’s ability to produce custom, patient-specific parts.

Jewellery

The technology’s fine detail makes it perfect for creating intricate jewellery designs and casting patterns. Designers can create prototypes or final pieces with remarkable accuracy and finish.

Small Mechanical Parts

Engineers can prototype gears, housings, and other small components with high accuracy. These parts are often used for testing assemblies or as end-use components in specialised devices.

Summary

DLP 3D printing is an excellent choice for projects requiring precision and a smooth finish, particularly in industries like healthcare, jewellery, and engineering. Its limitations in build size are outweighed by its speed and detail, making it a go-to option for intricate designs.

Talk to us

Contact us on 01763 249760 to discuss your requirements.

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