3D Printing Service:
Digital Light Processing
Parts in 1 to 4 days.
Digital Light Processing (DLP) is used for:
- Part Consolidation
- High Detail and Excellent Surface Finish
- Isotropic Mechanical Properties
Quality Matters | AS9100D Certified, ISO 9001:2015, ISO 13485:2016, & ITAR Registered
*Not all locations have all certifications and registrations. Parts requiring these will be made at facilities with the correct credentials.
Our Digital Manufacturing Process is Simple.
Upload a CAD file and request a quote.
Our team starts production after finalizing project specifications and accepting the quote with you.
When the part has been completed and finished, it passes through quality control.
After your part goes through quality control, our team ships the part(s) to you.
What is Digital Light Processing?
Digital Light Processing (DLP) is an additive manufacturing technology for 3D printing. It uses a digital micromirror device (DMD) to project light patterns onto a photosensitive resin precisely. This controlled exposure selectively cures the resin, creating each layer of the desired object. The process allows for fabricating highly intricate and complex parts, achieving exceptional surface finish and dimensional accuracy.
How does Digital Light Processing work?
An Additive Manufacturing (AM) Technician uploads your CAD file into the machine. The software then breaks down the file layer by layer. During this process, we carefully consider the build’s orientation and the placement of supports.
The Digital Light Processing (DLP) machine utilizes a photochemical process by projecting light into a UV-curable resin. As a result, the build platform rises after the light solidifies each layer, and this sequence is repeated until the entire build is complete.
After the DLP printing, an AM technician manually removes the component from the platform and support structure. The part then undergoes a curing process to attain its final mechanical properties, which is done using a post-curing apparatus (PCA) or a forced-circulation oven. Finally, the part goes to the finishing to achieve the desired surface quality.
Advantages to Digital Light Processing
Digital Light Processing technology has revolutionized the way products are designed and manufactured. The following are a few of the advantages of digital light processing:
- Excellent surface quality.
- Materials diversity.
- Very accurate.
- Ideal for dyeing, coloring, and other finishes.
Disadvantages to Digital Light Processing
While there are a lot of advantages to digital light processing, there are also some disadvantages to consider:
- Supports are needed.
- Over time materials can become brittle.
- Not suitable for outdoor uses, not UV stable.
Digital Light Processing at Prototek
Digital Light Processing Machine Companies:
Carbon
Digital Light Processing File Types:
Preferred Files: Solid, STEP, and DFX
Max Build Chamber Area:
7.4 x 4.6 x 12.8 in
Lead Time:
1 – 4 Days – Depending on materials.
Material:
EPU 40 & 41, EPX 82 & 86FR, FPU 50, LOCTITE® 3D IND405 Clear, MPU 100, RPU 70 & 130, SIL 30, UMA 90
Tolerances:
UMA 90: ± 0.005 in for the first inch and ± 0.002 in/in for each additional inch.
Two-part engineering materials depend on the geometries.
Layer Thickness:
Standard Resolution: 0.004 in
Fine Resolution: 0.002 in
Ultra Fine Resolution: 0.001 in
Prototek's Materials
EPU 40
Elastomeric Polyurethane
EPU 40 is a high-performance elastomer with excellent elastic recovery, tear resistance, and high impact strength. Consequently, it is an ideal material for producing durable and flexible parts, such as gaskets and seals.
General Accuracy
± 0.003 in + 0.010 in/in
Production Repeatability
(95% of Points)
± 0.003
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.015
0.04 in: 1.012
0.10 in: 1.010
0.30 in: 1.000
Tensile Strength
1,300 psi
Tensile Modulus
1,200 psi
Elongation @ Break
300%
Flexural Strength
N/A
Flexural Modulus
N/A
HD @ 264 psi
N/A
EPU 41
Elastomeric Polyurethane
EPU 41 offers superior flexibility, durability, resilience, tear resistance, and elongation properties. Moreover, it is an ideal choice when toughness and reliability are essential.
General Accuracy
± 0.003 in + 0.010 in/in
Production Repeatability
(95% of Points)
± 0.003
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.015
0.04 in: 1.012
0.10 in: 1.010
0.30 in: 1.000
Tensile Strength
2,200 psi
Tensile Modulus
1,160 psi
Elongation @ Break
300%
Flexural Strength
N/A
Flexural Modulus
N/A
HD @ 264 psi
N/A
EPX 82
Epoxy
Not only can EPX 82 produce parts with exceptional stiffness and strength, but it can also withstand high temperatures and harsh environments. Additionally, it can be easily post-processed to add features such as threaded inserts and other secondary operations.
General Accuracy
± 0.003 in + 0.013 in/in
Production Repeatability
(95% of Points)
± 0.002
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.025
0.04 in: 1.015
0.10 in: 1.004
0.30 in: 1.000
Tensile Strength
10 ksi
Tensile Modulus
410 ksi
Elongation @ Break
5%
Flexural Strength
19 ksi
Flexural Modulus
430 ksi
HD @ 264 psi
250° F
EPX 86FR
Epoxy
EPX 86FR is resistant to chemicals and has high thermal conductivity, enabling it to withstand harsh environments. Moreover, its flame-retardant properties make it suitable for use in parts that require compliance with flame retardancy standards, such as in the aerospace and automotive industries.
General Accuracy
± 0.003 in + 0.013 in/in
Production Repeatability
(95% of Points)
± 0.002
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.025
0.04 in: 1.015
0.10 in: 1.004
0.30 in: 1.000
Tensile Strength
10 ksi
Tensile Modulus
410 ksi
Elongation @ Break
5%
Flexural Strength
19 ksi
Flexural Modulus
430 ksi
HD @ 264 psi
250° F
FPU 50
Flexible Polyurethane
FPU 50 is a highly durable DLP material with excellent resistance to abrasion and impact, making it ideal for producing parts and products requiring flexibility and strength. Additionally, it has a Shore 71D, which means it has moderate flexibility while maintaining its shape. Moreover, it can withstand high temperatures and chemical exposure.
General Accuracy
± 0.002 in + 0.011 in/in
Production Repeatability
(95% of Points)
± 0.002
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.025
0.04 in: 1.005
0.10 in: 1.000
0.30 in: 1.000
Tensile Strength
4 ksi
Tensile Modulus
100 ksi
Elongation @ Break
7%
Flexural Strength
4 ksi
Flexural Modulus
120 ksi
HD @ 264 psi
110° F
LOCTITE® 3D IND405 Clear
LOCTITE® 3D IND405 is a clear, photoreactive resin used for 3D printing. This material allows for high-resolution printing with fast cure times. Moreover, its versatile formulation makes it suitable for a wide range of applications in industries such as medical, consumer goods, and automotive. Its high elongation and toughness make it resistant to cracking under stress.
Tensile Strength
6,000 ksi
Tensile Modulus
218 ksi
Elongation @ Break
120° F
Flexural Strength
N/A
Flexural Modulus
N/A
HD @ 264 psi
N/A
MPU 100
Medical Polyurethane
MPU 100 is a biocompatible material for the healthcare industry. It possesses exceptional strength, durability, and chemical resistance, making it ideal for medical equipment and devices.
General Accuracy
± 0.003 in + 0.001 in/in
Production Repeatability
(95% of Points)
± 0.002
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.003
0.04 in: 1.001
0.10 in: 1.000
0.30 in: 1.000
Tensile Strength
5 ksi
Tensile Modulus
190 ksi
Elongation @ Break
15%
Flexural Strength
6 ksi
Flexural Modulus
145 ksi
HD @ 264 psi
100° F
RPU 70
Rigid Polyurethane
Utilizing digital light processing, RPU 70 exhibits high stiffness, good tensile strength, and impact resistance properties. Consequently, it is well-suited for applications requiring durable and structurally sound parts. RPU 70 boasts a Shore D hardness rating of 70 and demonstrates exceptional resistance to abrasion, chemical exposure, and wear and tear.
General Accuracy
± 0.003 in + 0.011 in/in
Production Repeatability
(95% of Points)
± 0.002
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.031
0.04 in: 1.006
0.10 in: 1.001
0.30 in: 1.000
Tensile Strength
6 ksi
Tensile Modulus
245 ksi
Elongation @ Break
30%
Flexural Strength
8 ksi
Flexural Modulus
220 ksi
HD @ 264 psi
110° F
RPU 130
Rigid Polyurethane
RPU 130 provides high print accuracy with superior mechanical properties. Additionally, it boasts excellent stiffness, toughness, and impact resistance. Moreover, it has a high heat deflection temperature of up to 120°C, allowing it to endure high-temperature applications without degradation.
General Accuracy
± 0.003 in + 0.018 in/in
Production Repeatability
(95% of Points)
± 0.002
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.036
0.04 in: 1.022
0.10 in: 1.000
0.30 in: 1.989
Tensile Strength
5 ksi
Tensile Modulus
145 ksi
Elongation @ Break
100%
Flexural Strength
5 ksi
Flexural Modulus
130 ksi
HD @ 264 psi
130° F
SIL 30
Silicone
Silicone is highly compatible with the human body and boasts excellent elongation and tear strength, making it an ideal choice for medical and dental applications. It features a soft and flexible texture resembling rubber and has a Shore A hardness 30.
General Accuracy
± 0.005 in + 0.018 in/in
Production Repeatability
(95% of Points)
± 0.003
Additional XYZ Scale Factor
(Wall Thickness)
0.02 in: 1.047
0.04 in: 1.028
0.10 in: 1.012
0.30 in: 1.000
Tensile Strength
500 psi
Tensile Modulus
440 psi
Elongation @ Break
350%
Flexural Strength
N/A
Flexural Modulus
N/A
HD @ 264 psi
N/A
UMA 90
Urethane Methacrylate
UMA 90 has mechanical properties that surpass those of other materials. Its versatility makes it an excellent choice for various consumer products and industrial tooling applications. Furthermore, its superior strength and durability make it ideal for applications where other materials may fail. Moreover, its unique properties make it an attractive option for manufacturers looking for a reliable and effective solution.
General Accuracy
± 0.003 in + 0.001 in/in
Production Repeatability
(95% of Points)
± 0.002
Additional XYZ Scale Factor
(Wall Thickness)
N/A
Tensile Strength
44 ksi
Tensile Modulus
200 psi
Elongation @ Break
30%
Flexural Strength
7 ksi
Flexural Modulus
174 ksi
HD @ 264 psi
95° F
*Special processing may be required. Please notify us of any biocompatibility needs.
Design Recommendations
When designing digital light processing (DLP) parts, it’s essential to consider several key factors. Firstly, the part’s orientation during printing can significantly impact the final product’s quality. In DLP printing, bottom-up curing of layers means that features that taper or overhang can negatively affect print quality. However, this issue can be addressed using support or a well-designed model. Moreover, since DLP printing can produce parts with fine details, it’s crucial to ensure that small features are adequately supported and printed at an appropriate resolution. Finally, it’s essential to consider the post-processing needs of the part, such as cleaning and finishing, and plan accordingly. By considering these factors, designers can create high-quality, functional parts using DLP printing technology.
| Feature | Measurement | |
|---|---|---|
|
|
Connecting & Moving Parts |
Rigid: 0.01 in |
|
|
Escape Holes |
Rigid: 0.04 in Flexible: 0.04 in |
|
|
Embossing & Engraving |
Rigid: W: 0.008 in H/D: 0.004 in Flexible: W: 0.035 in H/D: 0.02 in |
|
|
Holes & Openings |
Rigid: 0.008 in |
|
|
Horizontal Spans |
Rigid: 0.12 in Flexible: 0.04 in |
|
|
Minimum Features |
Rigid: 0.004 in Flexible: 0.04 in |
|
|
Pin Diameter |
Rigid: 0.004 in Flexible: 0.04 in |
|
|
Supports & Overhangs |
Rigid: 25° Flexible: 45° |
|
|
Walls (Supported) |
Rigid: 0.008 in Flexible: 0.04 in |
|
|
Walls (Unsupported) |
Rigid: 0.012 in Flexible: 0.098 in |
| Feature | Measurement | |
|---|---|---|
|
|
Connecting & Moving Parts |
Rigid: 0.25 mm |
|
|
Escape Holes |
Rigid: 1 mm |
|
|
Embossing & Engraving |
Rigid: W: 0.2 mm H/D: 0.1 mm Flexible: W: 0.9 mm H/D: 0.5 mm |
|
|
Holes & Openings |
Rigid: 0.2 mm Flexible: 0.9 mm |
|
|
Horizontal Spans |
Rigid: 3.05 mm Flexible: 1 mm |
|
|
Minimum Features |
Rigid: 0.1 mm |
|
|
Pin Diameter |
Rigid: 0.1 mm |
|
|
Supports & Overhangs |
Rigid: 25°
Flexible: 45° |
|
|
Walls (Supported) |
Rigid: 0.35 mm Flexible: 2.5 mm |
|
|
Walls (Unsupported) |
Rigid: 0.2 mm Flexible: 1 mm |
Digital Light Processing Finishes
Prototek Digital Manufacturing is proud to offer a wide range of high-quality digital light processing (DLP) finishes tailored to match your specific manufacturing requirements perfectly. Leveraging our cutting-edge DLP technology, we guarantee exceptional surface quality, dimensional accuracy, and superior performance and reliability for all your parts. Trust us to deliver unmatched precision and consistency in every project, ensuring your manufacturing needs are met and exceeded.
Digital Light Processing Finishes
| Level | Process |
|---|---|
|
Natural |
Support faces are sanded, and layer lines are visible. |
|
Standard |
Support faces are sanded, and the entire part is bead-blasted for a matte/opaque finish with some layer lines visible (black will appear grey). |
|
Improved Exterior |
Exterior (cosmetic) surfaces are sanded, and the entire part is bead-blasted for a smooth matte finish. |
|
Improved All |
All accessible surfaces are sanded, and the entire part is bead-blasted for a smooth matte finish. |
|
Clear |
Natural finish with clear coat. The layer lines are still visible. |
|
Improved Clear |
All accessible surfaces are sanded smooth with a clear coat for optimal clarity on transparent materials. |
|
Primed Exterior |
Exterior (cosmetic) surfaces are sanded, bead-blasted, and primed grey. |
|
Primed All
|
All accessible surfaces are sanded, bead-blasted, and primed grey. |
|
Painted |
All accessible surfaces are sanded, bead-blasted, primed, and painted (provide a drawing with your paint specifications). |
|
Custom |
Custom finish. Let us know if your project requires special finishing. Please fill out our engineer-assisted quote form. |
Learn More About DLP
Through our resources, you can discover the complexities of DLP 3D printing and gain insights into creating top-notch designs specifically tailored for this cutting-edge technology.
A comparison of AM photopolymer technologies stereolithography, digital light processing, and hybrid photosynthesis.
Proud to be a part of the Carbon Production Network!
“The Carbon Production Network (CPN) is a global ecosystem of leading industry design firms and contract manufacturers who are experts in the Carbon idea-to-production platform. Find a CPN partner based on your needs and leverage the power of the Carbon platform to design, develop, and produce radically better products.” – Carbon
Prototek's
Other Additive Manufacturing Technologies
Why choose Prototek for your next digital light processing project?
Prototek is a leading provider of high-quality Digital Light processing services, specializing in prototyping and low-volume production. With over 30 years of manufacturing industry experience, Prototek offers a comprehensive range of Digital Light Processing solutions, including engineering support, rapid prototyping, tooling and mold making, and production manufacturing. Our skilled team of engineers and technicians utilize state-of-the-art technology and equipment, ensuring the highest standards of quality and precision. Prototek is committed to customer satisfaction and understands the importance of timely delivery. They offer competitive pricing, fast turnaround times, and exceptional customer service throughout the project process. Choose Prototek for your next Digital Light Processing project and experience first-hand their commitment to quality, innovation, and customer satisfaction.
