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- About Carbon DLS 3D Printing
Carbon DLS (digital light synthesis) is an industrial 3D printing process that creates functional, end-use parts with mechanically isotropic properties and smooth surface finishes. You can choose from both rigid and flexible polyurethane materials to meet your application needs for high impact-resistance components.
Common application for Carbon DLS are:
- complex designs that are challenging to mold
- need for isotropic mechanical properties and smooth surface finish
- production parts in materials comparable to ABS or polycarbonate
- durable components for end use
Carbon DLS Design Guidelines and Capabilities
Our basic guidelines for Carbon DLS (digital light synthesis) include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.
| US | Metric | |
| Normal Resolution | 7.4 in. x 4.6 in. x 12.8 in. | 189mm x 118mm x 326mm |
| US | Metric | |
| Normal Resolution | 0.004 in. | 0.100mm |
| US | Metric | |
| Structural Wall Thickness | 0.100 in. | 2.5mm |
| Supported Walls (Ribs, Bosses, etc.) | 0.040 in. | 1.0mm |
| Positive Features | 0.020 in. | 0.5mm |
| Negative Features/Holes | 0.025 in. | 0.6mm |
Carbon DLS Tolerances
Expected tolerances are +/- 0.010 in. (0.25mm) for the first inch plus +/-0.0015 in./in. (0.0015mm/mm) for each additional inch. Keep in mind that tolerances are not guaranteed on your first build of parts, however, we will work closely with you to help achieve critical dimensions. Please request critical dimensions when you upload your part, and our applications engineers will quickly review and provide feedback.
| Unfinished | Dots, or standing”nibs,” remain evident on the bottom of the part from the support structure remnants. |
| Natural (Default) | Supported surfaces are sanded down to eliminate the support nibs. |
Additional finishing processes to aid in assembly and meet your exact specifications are available. These include:
- Taps
- Threaded inserts
Carbon DLS Material Options
RPU 70 Rigid Polyurethane is manufactured through Carbon’s DLS (digital light synthesis) process. It is a tough all-purpose engineering grade material that comes in black and can be categorized as an ABS-like materials. Ideal part sizes for Carbon materials are 5 in. x 5 in. x 5 in. or less.
Primary Benefits
- Tough material
- Fatigue resistance
Compare Carbon DLS Material Properties
| Material | Color | Tensile Strength | Tensile Modulus | Elongation |
|---|---|---|---|---|
| Carbon RPU 70 | Black | 6 ksi | 245 ksi | 100% |
| Carbon FPU 50 | Black | 4 ksi | 100 ksi | 200% |
These figures are approximate and dependent on a number of factors, including but not limited to, machine and process parameters. The information provided is therefore not binding and not deemed to be certified. When performance is critical, also consider independent lab testing of additive materials or final parts.
| Material | Color | Tensile Strength | Tensile Modulus | Elongation |
|---|---|---|---|---|
| Carbon RPU 70 | Black | 41.4 MPa | 1,690 MPa | 100% |
| Carbon FPU 50 | Black | 27.6 MPa | 690 MPa | 200% |
These figures are approximate and dependent on a number of factors, including but not limited to, machine and process parameters. The information provided is therefore not binding and not deemed to be certified. When performance is critical, also consider independent lab testing of additive materials or final parts.
Surface Finish on Carbon DLS Parts
Shown below is a Carbon DLS part built with RPU 70 Rigid Polyurethane in normal resolution (0.004 in.).
Unfinished
With unfinished, you get varying aesthetics based on build orientation. Dots or standing nibs remain evident on the bottom of the part from the support structure remnants.
Natural Finish
With natural finishing, you get varying aesthetics based on build orientation. Standing nibs are sanded flat.
How Does Carbon DLS Work?
Carbon DLS uses CLIP (continuous liquid interface production) technology to produce parts through a photochemical process that balances light and oxygen. It works by projecting light through an oxygen-permeable window into a reservoir of UV-curable resin. As a sequence of UV images are projected, the part solidifies, and the build platform rises.
At the core of the CLIP process is a thin, liquid interface of uncured resin between the window and the printing part. Light passes through that area, curing the resin above it to form a solid part. Resin flows beneath the curing part as the print progresses, maintaining the continuous liquid interface that powers CLIP. Following the build, the 3D-printed part is baked in a forced-circulation oven where heat sets off a secondary chemical reaction that causes the materials to adapt and strengthen.
