The Advantages of Projection Micro Stereolithography, and The Disadvantages

Projection Micro Stereolithography (PµSL) is a cutting-edge 3D printing technology. Its unique characteristics offer several advantages but also come with some limitations. Let’s delve into the pros and cons of PµSL, as well as its various applications.

Pros of Projection Micro Stereolithography

High Accuracy

PµSL excels in creating highly accurate parts with fine details. The technology can achieve resolutions down to 10 microns, making it ideal for intricate designs.

Smooth Surface Finish

The combination of high resolution and small layer thickness (5-40µm) means parts have exceptionally smooth surfaces. This is typically 0.4-0.8µm Ra on the top and 1.5-2.5µm Ra on the sides. As a result, there is a much-reduced need for extensive post-processing.

Material Properties

PµSL parts are typically non-porous with near-isotropic material properties, ensuring consistency in mechanical performance.

Support Structures

When geometry allows, we are able to build directly to the bed meaning some parts do not need support supports. Given enough time we can fine-tune the size and strength of our supports leading to minimal witness marks requiring clean-up.

Versatility in Materials

PµSL supports a range of specialised materials, such as biocompatible and high-temperature resins, broadening its application scope. At Prototype Projects, we run these materials:

• HTL resin – this High Temp Low-viscosity, high-performance engineering material, has excellent strength and rigidity. Finished parts are also heat-resistant and withstand temperatures up to 114°C.
• BIO resin – a biocompatible resin suitable for non-implantable medical applications. This material can be sterilised and has passed numerous ISO 10993 biocompatibility tests.

Cons of Projection Micro Stereolithography

Limited Build Size

PµSL is generally suited for smaller parts. Our ultra-high-resolution machine has a build envelope of 100 x 100 x 75 mm. Larger components require multiple projections, which can complicate the process and reduce efficiency.

Cost

The high accuracy and quality of PµSL come at a price. The technology can be more expensive compared to other 3D printing methods, making it less suitable for budget-conscious projects.

Complexity of Setup

Achieving optimal results with PµSL requires careful calibration and setup, demanding skilled operators and increasing the initial setup time. Fortunately, we have a team of experts with vast experience using our PµSL machine.

Material Limitations

While versatile, the range of materials (listed earlier) available for PµSL is not as extensive as other 3D printing technologies like FDM or SLS, which might limit its application in some cases.

Applications of PµSL

Medical Devices

The accuracy and biocompatibility of PµSL make it ideal for producing components for medical and drug delivery devices. These parts often require stringent detail and smooth surfaces, both of which PµSL provides.

Biotechnology

In biotechnology, where detailed and accurate components are essential, PµSL is used to create parts for microfluidics and lab-on-a-chip devices.

Micro-Electromechanical Systems (MEMS)

PµSL’s ability to produce fine, detailed parts makes it suitable for manufacturing MEMS, which require high accuracy.

Optics

For optical components that demand smooth surfaces and precise geometries, PµSL is an excellent choice.

Consumer Electronics

Small, detailed parts used in consumer electronics, such as connectors and intricate housings, can be efficiently produced with PµSL.

Flat surface printing

Another feature of PµSL is that we can print directly onto flat surfaces of existing parts, such as microscope slides. This is advantageous because you can print channels/archway passages onto the slide, then turn the slide over and have an unobscured view (because it’s not yellow) of the fluid/blood travelling through the microfluidic channel.

Conclusion

Projection Micro Stereolithography (PµSL) offers a high-accuracy, smooth surface finish and versatility in material use, making it a valuable technology for prototype projects, especially where small, detailed parts are required. However, its cost, build size limitations, and complexity in setup need to be considered when selecting the right 3D printing method for a project. For applications in medical devices, biotechnology, MEMS, optics, and consumer electronics, PµSL stands out as a superior choice.

For more information on PµSL and to explore its potential for your prototype projects, click here.

Talk to us

If you have any questions about PµSL and/or an upcoming project, please contact us on 01763 249760. You can also request a quote via our website.