Figure 4 (DLP)
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DLP 3D Printing Service
Digital Light Processing (DLP) 3D Printing is a cutting-edge technology that uses a digital light projector screen to flash a single image of each layer all at once, allowing for quick and precise printing. This method is particularly effective for creating highly detailed and accurate parts with smooth surface finishes. This Additive Manufacturing process is ideal for a variety of application needs such as functional prototyping, direct production of end-use parts, moulding and casting, and includes rigid and durable thermoplastic-like, rubber-like, heat-resistant, and biocompatible capable materials.
What is DLP 3D Printing?
DLP 3D printing is a type of additive manufacturing that uses a digital light source to cure photopolymer resin layer by layer. The process begins with a vat of liquid resin, which is selectively exposed to light in the shape of the desired cross-section of the part. This light exposure causes the resin to solidify. The build platform then moves to allow the next layer to be cured. This process is repeated until the entire object is created.
DLP 3D printing offers several advantages over other 3D printing methods, including high resolution, fast print times, and excellent surface finish. It is particularly suited for applications that require fine details and smooth surfaces, such as snap-fits, connectors, jewellery, dental models, and intricate prototypes.
One key difference between DLP and SLA printing lies in the resin curing process. DLP printing uses a digital light source to project and cure an entire layer near instantly, resulting in faster print times. In contrast, SLA printing employs a laser to trace and cure layers, which can be more time-consuming.
Our Figure 4 DLP 3D Printing Solution?
At Formero, we leverage the advanced 3d Systems Figure 4 3D Printing technology to provide our clients with highest level of 3D Printing results. The Figure 4 platform is known for its high speed, accuracy, and versatility. It allows us to produce parts quickly without sacrificing quality, making it ideal for rapid prototyping and small production runs.
Our Figure 4 DLP solution offers:
- High Precision: Achieve intricate details with layer resolutions as fine as 10 microns.
- Fast Production: DLP 3D Printing produces fast results, making this technology suitable for manufacturing production runs.
- Material Versatility: Access to a wide range of materials, including rigid, flexible, flame retardant and castable resins.
- Consistent Quality: Reliable and repeatable results for every print job.
- Scalability: This direct 3D production allows for up to 10,000 parts to be manufactured per month. Formero has the capability to run different materials and different jobs at the same time using multiple printers.
- Six Sigma Repeatability: Figure 4 solutions deliver accurate parts with six sigma repeatability in a diverse range of robust, production-grade materials for immediate part turnaround without the costs and delays of tooling.
Materials Available.
Pro Black 10
Production-grade additive manufacturing material with game-changing thermoplastic-like mechanical properties and long-term environmental stability.
Figure 4® PRO-BLK 10 delivers on the promise of additive manufacturing with true direct digital production of plastic parts. Go from CAD to manufacturing line in one day with tool-less, same day part production.
With a fast print speed and simplified post-processing that includes a single curing cycle and single solvent cleaning, this material delivers exceptional throughput. It is a high precision resin producing parts with a smooth surface finish and sidewall quality, and has excellent mechanical properties and long-term environmental stability that brings a new level of assurance to 3D production.
Applications
- Tool-less, same day production
- Direct production of small black plastic parts such as motor housings, connectors, snap-fits, automotive interior and other general-use parts
- Digital production to replace injection moulding or soft tooling processes
Benefits
- Improved environmental stability of mechanical and performance properties over time
- Excellent surface quality and repeatability
- Accurate, low distortion material
Features
- 70°C heat deflection temperature
- Durability and strength
- Biocompatible capable per ISO10993-5 and ISO10993-10
- Exhibits thermoplastic behaviour in necking at tensile break point
Technical Specs
| Tensile Strength: | 63 MPa |
| Elongation at Break: | 12% |
| Flexural Strength: | 92 MPa |
| Impact Strength: | 24 J/m (notched Izod) |
| Colour: | Black |
| Build Size: | 124.8×70.2×346 mm |
| Layer Thickness: | 0.04 mm |
For more technical data download the material data sheet.
Rubber-65A Black
A mid-tear strength, production-grade rubber combined with Shore 65A hardness and a high elongation at break.
Figure 4® RUBBER-65A BLK material is specially formulated to address key customer needs for rubber parts featuring production performance properties and production mechanical properties tested according to industry standards.
Figure 4® RUBBER-65A BLK is a mid-tear strength, high elongation at break, Shore 65A material for the production of medium hard rubber parts with slow rebound, for applications such as grips, handles, gaskets, bumpers, seals, vibration dampening components and more.
Applications
- Air/dust gaskets
- Seals and housings
- Vibration dampener and pipe spacers
- Bumpers
- Grips and handles
Benefits
- Production performance properties
- Long-term stability
- UL94 HB flammability test standards
Features
- Biocompatible capable per ISO 10993-5 and ISO 10993-10
- High elongation at break
- Shore-A of 65 (medium hard rubber)
- Mid-tear strength
Technical Specs
| Tensile Strength: | 5 MPa |
| Elongation at Break: | 126% |
| Colour: | Black (semi-translucent) |
| Build Size: | 124.8×70.2×346 mm |
| Layer Thickness: | 0.04 mm |
For more technical data download the material data sheet.
Tough 60C White
PRODUCTION RIGID | White plastic for long-term use parts with a good combination of impact strength, elongation, and tensile strength.
Figure 4® Tough 60C White is a versatile, biocompatible-capable production-grade white material with good impact strength, elongation, and tensile strength. It provides long-term environmental stability and long-lasting white colour with an injection moulded-like surface quality. This material is recommended for high mechanical load-bearing batch production medical parts that remain functional and stable for years.
This resin features a 65˚C heat deflection temperature and 23% elongation at break and is excellent for brackets, snaps, and clips due to a 7.1% elongation at yield. Fast print speeds and simplified post-processing speeds enable exceptional throughput.
Figure 4 Tough 60C White is tested to 8 years of indoor and 1.5 years outdoor mechanical performance per ASTM D4329 and ASTM G194 methods, ensuring that printed parts remain functional and stable for long periods in real-world conditions.
Applications:
- Clinical trials and medical devices such as tools, handles, and small plastic parts
- Load-bearing parts such as handles, cranks, knobs, and levers
- Structural parts like brackets, snap-fits, and custom fasteners
- Small parts requiring detail and accuracy in consumer products, wearable devices, and general use
- Functional prototyping and biocompatible end-user parts
Benefits
- Long-term use parts for indoor and outdoor applications
- No secondary thermal cure required
- Clean, long-lasting bright white color
- Excellent surface quality, accuracy & repeatability
- Autoclavable
Features
- Long-term indoor and outdoor environmental stability of mechanical properties and color; tested out to 8 and 1.5 years (respectively) per ASTM methods
- Biocompatible-capable per ISO10993-5 and ISO10993-10*
- 65°C HDT at 0.455MPa
- 23% elongation at break
- 7.1% elongation at yield
- 34 J/m notched impact strength
- 1500 MPa tensile modulus
- UL94 HB flammability
- Sterilisation through Autoclave
Technical Specs
| Tensile Strength: | 35 MPa |
| Elongation at Break: | 23% |
| Flexural Strength: | 52 MPa |
| Impact Strength: | 34 J/m |
| Colour: | White |
| Build Size: | 124.8×70.2×346 mm |
| Layer Thickness: | 0.04 mm |
For more technical data download the material data sheet.
Medical Amber 10
Biocompatible, sterilisable, translucent and high temperature resistant resin.
A rigid, translucent amber material designed for medical and industrial applications where biocompatibility, sterilisation, thermal resistance, and fluid flow visualisation are required. It is capable of meeting ISO 10993-5 and -10 standards for biocompatibility (cytotoxicity, sensitisation, and irritation) and can be sterilised via autoclave. The material performs reliably at temperatures over 100°C and delivers highly accurate parts with crisp details, excellent feature resolution, and high definition.
Applications:
- Surgical drill guides, splints
- Fluid handling manifolds
- Elevated temperature testing
- Parts with high definition details
- Threaded assemblies
- Visualisation and fluid flow models
Benefits:
- Meets ISO 10993-5 & 10993-10 standards
- Excellent visualisation for parts requiring evaluation of internal features
- High temperature testing
- True-to-CAD accuracy and crisp feature detail
Features:
- Biocompatible
- Sterilise by autoclave
- Thermal resistance over 100°C
- Excellent humidity/moisture resistance
Technical Specs
| Tensile Strength: | 69 MPa |
| Elongation at Break: | 4% |
| Flexural Strength: | 111 MPa |
| Impact Strength: | 18 J/m |
| Colour: | Translucent Amber |
| Build Size: | 124.8×70.2×346 mm |
| Layer Thickness: | 0.04 mm |
For more technical data download the material data sheet.
Frequently Asked Questions (FAQ)
DLP boasts rapid production capabilities, coupled with high precision and intricate detailing. These attributes position it as a favoured option for crafting precise prototypes. Notably, DLP substantially diminishes lead times and facilitates swifter design iterations.
Yes, DLP holds the capability to create parts featuring production-grade attributes such as refined surface finish, textures, dimensional accuracy, and notable mechanical performance. This versatility renders it suitable for a range of end-use applications.
DLP is compatible with an array of materials, encompassing engineering plastics and elastomers. This versatility in material options empowers the production of parts showcasing a wide spectrum of mechanical properties and functional capabilities.
Certainly, DLP thrives in crafting intricate and delicate designs with remarkable accuracy and resolution. Its ability to deliver a smooth surface finish and excellent sidewall quality further enhances its suitability for such tasks. The layer-by-layer methodology of DLP ensures the precise replication of even the most intricate details.
DLP serves a variety of industries including automotive, healthcare, aerospace, concept models, and consumer electronics. Its adeptness in producing intricately detailed and functional parts addresses a broad spectrum of requirements within these sectors.
No, there is no difference between Digital Light Processing (DLP) and Figure 4. The term “Figure 4” was coined by 3D Systems, the developer of the Figure 4 systems Formero has deployed. Both names pertain to the same additive manufacturing process, employing a UV light source to selectively cure liquid resin layer by layer, resulting in the fabrication of intricately detailed and precise 3D objects.
The timeline for DLP projects is influenced by factors such as part complexity, size, post-processing requirements, and the quantity being produced. DLP is notably swift in comparison to other processes and can frequently result in the completion of small geometries within hours, rather than days.
