DLS (Digital Light Synthesis) printing is an industrial 3D printing process that produces functional, end-use parts with superior mechanical properties and smooth surfaces.
Understanding DLS Technology
DLS, or Digital Light Synthesis, is a unique approach to additive manufacturing that differs significantly from other 3D printing methods like FDM or SLS. Instead of building parts layer by layer, DLS utilizes a continuous liquid interface production process. This process involves projecting light through a transparent window into a liquid resin bath, causing the resin to solidify.
Key Characteristics of DLS Printing:
- Continuous Process: DLS enables the creation of parts continuously, which means a significant speed advantage compared to traditional layer-by-layer techniques.
- Mechanically Isotropic Properties: Parts made with DLS exhibit nearly uniform strength in all directions, unlike some traditional 3D printed parts that are weaker along layer lines.
- Smooth Surface Finishes: DLS printed parts generally have a smooth and polished surface finish, reducing the need for post-processing.
- Variety of Materials: A range of both rigid and flexible polyurethane materials can be used with DLS, making it suitable for diverse applications that require high impact resistance.
How DLS Printing Works
- Liquid Resin: The process starts with a liquid photopolymer resin.
- Light Projection: A digital light projector shines light through a transparent window into the resin.
- Continuous Curing: The light cures the resin and a continuous motion of the build platform draws the cured part from the resin bath
- Part Creation: The continuous curing creates a solid, precise part with excellent mechanical properties and high-quality surface finishes.
Applications of DLS Printing
DLS is used across multiple industries thanks to its ability to create high-performance, end-use parts with desirable characteristics. Examples of applications include:
- Automotive: Manufacturing durable, lightweight components for vehicles.
- Consumer Products: Creating high-quality, complex geometries for products.
- Medical: Producing biocompatible and precise medical devices and prototypes.
- Industrial: Making rugged, custom parts for manufacturing applications.
Material Options
DLS printing uses specially designed polyurethane resins, which are available in both rigid and flexible options. This allows engineers to tailor material properties to meet the specific functional requirements of different applications, especially where high impact resistance is essential.
| Material Type | Characteristics | Ideal Use Cases |
|---|---|---|
| Rigid | High strength, stiffness, and durability | Structural components, casings, housings |
| Flexible | Elasticity, impact resistance, and energy absorption | Seals, gaskets, cushions, flexible connectors, and impact-resistant parts |
In conclusion, DLS printing is a powerful industrial 3D printing method offering unique advantages in material properties, surface finishes, and production speed. It’s well-suited for creating functional, end-use parts across diverse applications requiring high performance.
