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3ders.org – Autodesk shares tips on speeding up Ember resin 3D .

by • March 9, 2016 • No Comments

Mar 10, 2016 | By Alec

3D printing has so many advantages, that you can approximately consumely forget of its largest disadvantage: speed, or lack thereof. It is one of the many worthwhile facts holding back adoption of 3D printing as a legitimate making tool. Fortunately, several ongoing projects are working to optimize that speed, and Autodesk has only shared a handy guide for optimizing their own Ember 3D printing device through software and material optimization and exploiting the quite nature of resin 3D printing device. Through their approach, they managed to reach top speeds of 440 mm per hour, 24 times faster than the original 18 mm per hour.
As they explain in their guide, the lack of speed is a dreadful bottleneck. “The output of today’s 3D printing devices (across all technologies) is much slower than that of other making systemes such as CNC milling, injection molding or forging. As a outcome, the cost to manufacture 3D printed parts is prohibitive and frequently outweighs any benefit of the optimized part,” they say. “If the speed of 3D printing increases, and so it can be transformed into a viable making technique and open up a host of opportunities.”

But this can require consume complexware and software optimization to realize, they are perfectly
right to point out that a thing as easy as clever turn it into can go a long way. This is illustrated in an insightful guide, that equite owner of a resin-based 3D printing device should check out. “The techniques that we describe here apply to the whole class of DLP SLA printing devices and can be replicated on many various systems,” they say. “We want to go on advancing the say of additive making and we assume the most manufactures it to in making systemes to come of approaches that combine complexware, materials, and software. […] Our goal is to drive the additive making industry forward by developing a connected ecosystem that can provide turn it intoers and manufacturers the software they require unlock this class of technology.”

Whilst there are a few steps involved in optimizing your 3D printing device, as you can see in the guide on Instructables, the core solution can be discovered in the resin 3D printing system itself. The resin layers generated by the Ember are, of course, lifted out of the bed and are subjected to an huge suction force of the resin. “These suction forces are inversely proportional to the thickness of uncured resin, in other words, the thicker the uncured layer of resin the lower the separation force. The suction forces are in addition proportional to the surface area of the part, the larger the part, the greater the forces,” they explain.
To decrease those forces, a shear separation mechanism is used called Minimal Force Mechanics. In a nutshell, it reduces suction forces by rotating the resin tray. “It allows for Ember to reliably, turn it into parts with amazing additional detail. BUT it takes around 2-3s per layer and thus represents of 50% of the print time and limits the print speed at 25-micron layers to 18 mm/hour,” they say. Through this guide, that separation step is removed all together, with the optimization of software and materials allowing separation instead.

The initially solution fundamentally consists of via another type of resin, called PR48-High-Speed. It outcomes in thicker layers and cures much faster. You can, yet, have to tune the existing PR48 resin by yourself – for that you can find assist in the guide. “The UV blocker concentration in PR48-High-Speed has been reduced by a factor of 4 compared to PR48 to allow it to cure swifter and to a deeper depth,” they say.
Step two consists of configuring the Ember 3D printing device, that you can do through emberprinting device.com or by SSH into the printing device and editing the file /var/smith/config/settings. Simply follow the steps in the guide to eliminate the separation step and begin printing at 250 micron layers. So download the supplied example file (featuring a lattice structure that reduces the surface area per layer), and you can in fact 3D print at immense speeds.
It is not magic. Key is the lattice structure that reduces the global surface area to less than 15% of a slice. “The global surface area must stay at a lower place 15% so that the suction forces, that remember are proportional to surface area, do not become greater than the durablity of the cured resin, the tear durablity of the PDMS window and the normal force that the linear drive and motor can donate,” they explain. Any higher, and the version fails. The optimized resin, meanwhile, empowers swifter curing and a deeper depth by reducing the photo-inhibitor.

Of course this is not a magical solution for swift 3D printing, as the geometry is several limited to the global surface area percentage, the local surface area, the rate of alter of position of local surface area, and the durablity of the cured material. This rules out a lot of prints immediately. “For a begin, you can’t print standard DLP SLA parts like dental restorations, hearing aids or rings. Even thin walled parts like ear shells and dental copings have too much surface area per layer to work (at very least on Ember). We have discovered that all the parts printed via this technique require to be thin strutted lattices,” they say.
But there are a few possibilities. The Spark team have turn it intod a CAD tool that transforms your solid files into lattice structures that can be 3D printed via this swift method. “For example, if we take the ubiquitous Stanford Bunny we can turn it into a lattice representation and and so use Print Studio to slice it for Ember, but it’s complex to control the end product via this technique. To that successfully turn it into for high-speed DLP, you require turn it into software that understands the system, the complexware and materials,” the Autodesk team says.
But instead of seeing this as a easy trick for swift 3D printing, this guide can in addition been seen as a new approach for 3D printing optimization. It is not only of complexware or materials; there’s yet a whole turn it into dimension that can be taken advantage of. “That’s why we’re assembling a connected ecosystem of complexware, software and materials so we can donate production eager additive making workflows,” they complete.

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