Image courtesy Protolabs
 
The technology from Carbon 3D is significantly faster than other additive manufacturing processes. In one example, Protolabs reported that the batch production of 28 units was more than four times faster than using stereolithography (SLA). Also, according to the company, these time savings are even greater for taller parts.

 
While DLS from Carbon 3D has been used for elastomeric materials, Protolabs is one of the first to apply it to rigid parts for production.
 
The 3D printed components from the epoxy resin EPX 82 have high strength, long term durability and functional toughness with mechanical properties comparable to glass filled polymers. Combining these properties with its high chemical and thermal resistance make EPX 82 components an excellent choice for many final products.
 
Commenting on these advances, Daniel Cohn, Managing Director of Protolabs Additive Manufacturing, said: “This technology combined with our engineering expertise allows us to provide plastic components for series production using additive manufacturing for the first time. It takes the technology well beyond its traditional application of prototyping, product development and low scale production.
 
“It’s well known that additive manufacturing can produce geometries and structures that are simply not possible using other manufacturing technology. In the past speed was a limiting factor for mass production.
 
“Using DLS from Carbon 3D to manufacture parts from the epoxy resin EPX 82 has changed that narrative. It means that companies can now have finished products in the shortest possible time without having to produce complex injection moulds. The process allows engineers design flexibility to produce components with complex geometries and a high surface quality that are extremely durable.”
 
Dr Philipp Amend, Director of 3DP Process and Customer Projects at Protolabs said: “As this is a new process, we will advise potential customers on whether DLS is suitable for their components.
 
“In effect we are offering an outsourced research and development department through to production for additive manufacturing. We can work with a potential customer to develop a suitable design that we can validate through test prints, reiterate if necessary and then proceed straight to production of those parts.  This process allows the development and refinement of parts through to delivery of final components in a fraction of the time required by other processes.”
 
In addition to EPX 82, Protolabs also offers EPX 86FR, FPU 50 and RPU rigid polyurethane as materials using DLS. Commenting on this capability, Joe Batdorf, Director for Production Success from Carbon 3D said: “We are excited to see Protolabs expand their fleet of Carbon printers and add production-focused capacity. Their team of product development specialists, combined with their material expertise, make them a trusted partner.”