From Prototyping to Production: Rethinking Materia
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Posted On: 09/19/2017 11:15:27 PM
From Prototyping to Production: Rethinking Materials for Additive Manufacturing, Jason Rolland, Carbon (USA)
Additive manufacturing processes use time-consuming, stepwise layer-by-layer approaches for part fabrication. We demonstrate the continuous production of monolithic polymeric parts with feature resolution below 100 micrometers. Digital Light Synthesis (DLS) is achieved with an oxygen-permeable window below the ultraviolet image projection plane, which creates a “dead zone” (persistent liquid interface) where photopolymerization is inhibited between the window and the polymerizing part. We define critical control parameters and show that complex solid parts can be drawn out of the resin at rates 25-100X that of conventional technologies.
Additionally, we show that DLS enables a wide range of new and commercially relevant materials. These include: tough, resilient elastomers; rigid, impact-resistant plastics with excellent abrasion resistance; flexible materials capable of producing living hinges; high-temperature cyanate ester resins; and other novel polymer formulations. These materials open possibilities across a range of industries including automotive, footwear, medical, aerospace, wearables, and many others.
The combination of rapid, layerless printing with high-performance engineering polymers having a range of mechanical properties represents a major step toward fulfilling the promise of additive manufacturing.
Additive manufacturing processes use time-consuming, stepwise layer-by-layer approaches for part fabrication. We demonstrate the continuous production of monolithic polymeric parts with feature resolution below 100 micrometers. Digital Light Synthesis (DLS) is achieved with an oxygen-permeable window below the ultraviolet image projection plane, which creates a “dead zone” (persistent liquid interface) where photopolymerization is inhibited between the window and the polymerizing part. We define critical control parameters and show that complex solid parts can be drawn out of the resin at rates 25-100X that of conventional technologies.
Additionally, we show that DLS enables a wide range of new and commercially relevant materials. These include: tough, resilient elastomers; rigid, impact-resistant plastics with excellent abrasion resistance; flexible materials capable of producing living hinges; high-temperature cyanate ester resins; and other novel polymer formulations. These materials open possibilities across a range of industries including automotive, footwear, medical, aerospace, wearables, and many others.
The combination of rapid, layerless printing with high-performance engineering polymers having a range of mechanical properties represents a major step toward fulfilling the promise of additive manufacturing.
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