New Fictiv 3D Printing Material/Process: CarbonDLS

Time to read: 6 min

Fictiv, the operating system for custom manufacturing, today announced Carbon Digital Light Synthesis (DLS) 3D printing technology as part of our robust, production-level 3D printing capabilities. Carbon DLS printing offers injection molding level repeatability alongside the ability to manufacture complex geometries, similar to our stereolithography (SLA) and fused deposition modeling (FDM) options. Within this new offering is the capability to provide carbon DLS parts from the following proprietary materials: 

• CE 221
• EPU 40
• EPU 41
• EPX 82
• EPX 86FR
• FPU 50
• MPU 100
• RPU 70
• SIL 30
• Loctite 3D IND405 Clear
• Loctite 3D IND147
• Loctite 3D 3843
• UMA 90

What is Carbon Digital Light Synthesis?

The carbon DLS process involves 3D printing of a liquid polymer resin, which is selectively cured using the digital light projection process, similar to SLA 3D printing. The bottom of the liquid polymer resin tank has an oxygen-permeable membrane, which creates a zone of uncured resin beneath the cured resin, known as the “dead zone.” This “dead zone” allows layers to be built on each other without the build layers sticking to the platform, enabling simplified removal of the part.

What Are the Advantages of Carbon Digital Light Synthesis? 

Carbon DLS 3D printing offers parts with high homogeneity due to the nature of the curing process. Parts printed with carbon DLS manufacturing offer isometric properties; in other words, you get the same strength parts regardless of print orientation. The carbon DLS process is also advantageous for the following reasons: 

1. Reduce weight and maximize strength with innovative material selection.
2. Higher production repeatability with printing that creates isotropic parts to ensure your assemblies fit properly the first time (within 0.10”).
3. Injection molding results in reach at lower quantities; most cost-effective for 20-500 parts or geometries that are traditionally difficult to injection mold (such as undercuts or undrafted walls).
4. Rapid print speeds Carbon DLS can achieve rapid print speeds compared to traditional SLA methods, thanks to its continuous liquid interface production (CLIP) technology
5. Fully homogeneous parts, without voids or delamination. The digital light projection system ensures high-resolution printing, allowing for intricate details and fine surface finishes. The oxygen-permeable membrane and continuous printing process contribute to consistent layer-to-layer curing and reduce the risk of warping or deformation.
6. A wide range of material options: Carbon offers a range of proprietary resins that can exhibit characteristics such as high strength, durability, flexibility, and biocompatibility, making them suitable for various applications.
7. Production level parts: Carbon DLS is often used for both prototyping and end-use production, making it suitable for various industries, including automotive, aerospace, healthcare, and consumer goods.

How Do Carbon DLS Materials Compare to Common Thermoplastics?

You can rest assured that there is a comparable carbon material with properties similar to your favorite thermoplastic. There are many options for comparable carbon materials for the most popular thermoplastics. Utilize the chart below to learn more about how these materials stand up to each other:

Carbon DLS as a Substitute for Injection Molded Parts

Carbon DLS has a wide array of possible use cases. It’s often used for prototyping and end-use production, making it suitable for various industries, including automotive, aerospace, healthcare, and consumer goods. Another interesting use case for Carbon DLS is as a substitute for injection molded parts. 

In fact, for medium-level quantities (below mass-production or around 20-500 parts), Carbon DLS offers the following advantages over injection molding: 

1. No tooling costs upfront; maximize your cash flow by reducing capital expenditures
2. Ability to print complex geometries which are often problematic when utilizing injection molding, such as undercuts and walls without draft angles
3. Higher repeatability and homogeneity 

To learn more about Fictiv’s 3D printing solutions, visit the company’s website.

About Fictiv

Fictiv is the operating system (OS) for custom manufacturing that makes it faster, easier, and more efficient to source and supply mechanical parts. Its intelligent OS, supported by best-in-class operations talent, orchestrates a network of highly vetted and managed partners around the globe for fast, high-quality manufacturing, from quote to delivery. To date, Fictiv has manufactured more than 25 million parts for early-stage companies and large enterprises, helping them innovate with agility and get products to market faster.