High-Quality
Digital Light Processing
Parts

Parts in 1 to 4 days.

Digital Light Processing (DLP) is used for:

Quality Matters  |  AS9100D Certified, ISO 9001:2015, ISO 13485:2016, & ITAR Registered

Certifications and Registrations

*Not all locations have all certifications and registrations. Parts requiring these will be made at facilities with the correct credentials.

AM Technology | Digital Light Processing (DLP)
Table of Contents

What is Digital Light Processing?

Digital Light Processing (DLP) is a form of 3D printing that uses a UV-sensitive liquid resin cured through a digital light projector. Once the printing process is finished, our AM technicians clean the part, remove any supports, and subject it to UV and thermal curing if needed.

DLP 3D printing is particularly suitable for projects requiring high levels of detail and finishing in various production-grade materials. This technology can produce components with various durometers and characteristics, from supple silicone to rigid high-temp cyanate ester. It is an excellent choice for small end-use components, lightweight metal part replacements, functional, high-detail prototypes, jigs, and fixtures.

How does Digital Light Processing work?

An AM Technician uploads your CAD file into the machine, and the software breaks it down layer by layer. We also consider the build’s direction and the supports’ placement. The Digital Light Processing machine uses a photochemical process by projecting light into a UV-curable resin. The build platform rises after the light solidifies each layer. These steps repeat until the build is complete.

After the DLP printer, an AM technician manually removes the component from the platform and support structure. The part is then cured to its final mechanical properties by utilizing a post-curing apparatus (PCA) or forced-circulation oven before moving on to the final surface finishing.

AM Technology | Digital Light Processing (DLP)

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:

Disadvantages to Digital Light Processing

While there are a lot of advantages to digital light processing, there are also some disadvantages to consider:

 

Digital Light Processing at Prototek

OEM:

Carbon

Max Build 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 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

Material

Description

Characteristics

More Information

EPU 40
Elastomeric Polyurethane

It is a high-performance elastomer with excellent elastic recovery, tear resistance, and high impact strength. It is an ideal material for producing durable and flexible parts, such as gaskets and seals.

  • Black
  • Biocompatible*
  • Chemical Resistant
  • Elastomeric
  • Flexible
  • Impact Resistant
  • Tear and Wear Resistant

EPU 41
Elastomeric Polyurethane

It is an elastomeric polyurethane material with superior flexibility, durability, resilience, tear resistance, and elongation properties. It is an ideal choice when toughness and reliability are essential.

  • Black
  • Biocompatible*
  • Chemical Resistant
  • Elastomeric
  • Fatigue Resistant
  • Flexible
  • Impact Resistant
  • Wear and Tear Resistant

EPX 82
Epoxy

It can produce parts with exceptional stiffness and strength and withstand high temperatures and harsh environments. Additionally, it can be easily post-processed to add features like threaded inserts and other secondary operations.

  • Black 
  • Good for Snap Fits
  • High Strength
  • Impact Resistant
  • Rigid
  • Temperature Resistant

EPX 86FR
Flame Retardant Epoxy

The material is resistant to chemicals and has high thermal conductivity, enabling it to withstand harsh environments. 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. 

  • Black 
  • Chemical Resistant
  • Flame Retardant
  • Good for Snap Fits
  • High Strength
  • Impact Resistant
  • Rigid
  • Temperature Resistant

FPU 50
Flexible Polyurethane

It is a highly durable DLP material with excellent resistance to abrasion and impact, making it ideal for producing parts and products that require flexibility and strength. The material has a Shore A hardness of 50, which means it has moderate flexibility while maintaining its shape. This material is also able to withstand high temperatures and chemical exposure. 

  • Black 
  • Abrasion Resistant
  • Fatigue Resistant
  • Good for Snap Fits
  • High Strength
  • Impact Resistant
  • Wear and Tear Resistant

LOCTITE® 3D IND405 Clear is a clear/translucent, photoreactive resin for 3D printing. This material offers high-resolution printing capabilities with fast cure times. A versatile formulation, it is 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. 

  • Clear/Translucent
  • High Strength
  • Impact Resistant
  • Rigid

MPU 100

Medical Polyurethane

It is a high-performance thermoplastic material designed for the healthcare industry. This material possesses exceptional strength, durability, and chemical resistance, making it ideal for medical equipment and devices.

  • White
  • Abrasion Resistant
  • Biocompatible*
  • Chemical Resistant
  • High Detail/High Resolution
  • High Strength

RPU 70

Rigid Polyurethane

This digital light processing material possesses high stiffness, good tensile strength, and impact resistance properties, which make it ideal for applications that require parts with high durability and structural integrity. RPU 70 has a Shore D hardness rating of 70 and provides excellent resistance to abrasion, chemical exposure, and wear and tear.

  • Black
  • Biocompatible*
  • Flame Resistant
  • Good for Snap Fits
  • High Ductility
  • High Strength
  • Rigid
  • Temperature Resistant

RPU 130

Rigid Polyurethane

It offers high print accuracy with superior mechanical properties, including excellent stiffness, toughness, and impact resistance. It has a high heat deflection temperature of up to 120°C, meaning it can withstand high-temperature applications without degrading.

  • Black
  • High Strength
  • Impact Resistant
  • Rigid
  • Temperature Resistant

SIL 30

Silicone

This material is highly compatible with the human body and has excellent elongation and tear strength, making it a perfect choice for medical and dental applications. It has a soft and flexible texture like rubber and has a Shore A hardness of 30.

  • Grey
  • Biocompatible*
  • Elastomeric
  • Flexible
  • Wear & Tear Resistant

UMA 90

Urethane Methacrylate

This digital light processing material’s mechanical properties surpass those of other materials. Its versatility makes it an excellent choice for various consumer products and industrial tooling applications. Its superior strength and durability make it ideal for use in applications where other materials may fail, and its unique properties make it an attractive option for manufacturers looking for a reliable and effective solution. 

  • Multiple Colors
  • Biocompatible*
  • Chemical Resistant
  • High Strength
  • Rigid

*Special processing may be required. Please notify us of any biocompatibility needs.

Design Recommendations

Designing digital light processing (DLP) parts requires careful consideration of several vital factors. The orientation of the part during printing can have a significant impact on 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 can be mitigated by using supports or a strategically designed model. 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.

Design Manual Poster
Feature Measurement

Connecting & Moving Parts

Rigid: 0.12 in
Flexible: 0.04 in

Escape Holes

Rigid: 0.04 in
Flexible: 0.04 in

Embossing & Engraving

0.02 in SIL 30
0.01 in all other material

Holes & Openings

0.002 in

Horizontal Spans

2x overhangs

Minimum Features

Rigid: 0.004 in
Flexible: 0.04 in

Pin Diameter

Rigid: 0.004 in
Flexible: 0.04 in

Supports & Overhangs

0.04 in EPU 40 &41 & SIL 30
0.08 in RPU 70 & 130, FPU 50, & EPX 82
0.12 in MPU 100 & UMA 90

Walls (Supported)

0.06 in RPU 130, EPX 82, & SIL 30
0.04 in all other materials

Walls (Unsupported)

0.1 in

Feature Measurement

Connecting & Moving Parts

Rigid: 3 mm
Flexible: 1 mm

Escape Holes

Rigid: 1 mm
Flexible: 1 mm

Embossing & Engraving

0.5 mm SIL 30
0.3 mm all other materials

Holes & Openings

0.04 mm

Horizontal Spans

2x Overhangs

Minimum Features

Rigid: 0.1 mm
Flexible: 1 mm

Pin Diameter

Rigid: 0.1 mm
Flexible: 1 mm

Supports & Overhangs

1.0 mm EPU 40 & 41 & SIL 30
2.0 mm RPU 70 & 130, FPU 50, EPX 82
3.0 mm MPU 100 & UMA 90

Walls (Supported)

1.5 mm RPU130, EPX 82, & Sil 30
1 mm all other materials

Walls (Unsupported)

2.5 mm

Digital Light Processing Finishes

To ensure a high-quality final product, several steps must be taken when finishing and post-processing digital light processing (DLP) projects. Firstly, cleaning the printed object thoroughly is important to remove any excess resin. This can be accomplished by rinsing it with isopropyl alcohol and allowing it to air-dry. Secondly, the object may require curing using a UV light to harden the resin completely. This step can prevent the object from warping or cracking. Finally, sanding and painting may be necessary to achieve the desired finish. Sanding can help to smooth out rough surfaces or visible layer lines, while painting can add color and texture to the object. Overall, finishing and post-processing are essential components of DLP printing to ensure the final product looks great and functions well.

Digital Light Processing: EPX 86FR
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.

What do our customers say about us?
They are competitively priced for their services and a very personable team to work with. If you haven't used them - do it! You'll have a lifelong vendor you be happy with that repeatedly goes above and beyond what is asked.
Product Designer
We are extremely happy with the quality of the parts as well as the level of service - thanks!
VP Product Designer