Design for DLS
Application Selection

39min
What Makes a Successful Application
This module intends to unlock the mystery of what makes a successful application and provide a high-level thought process for application/part identification. This method is not the only answer for identifying the best applications, but provides a good starting point for selecting potential applications while disqualifying unsuitable ones.
There are many examples of successful additive applications. To review some of Carbon customer's successes, study the case studies on the Carbon website, or those outlined below﻿. As these cases are reviewed, some main categories of business value become apparent: Design Freedom, Economic Advantages, and Part Consolidation. The value associated with these categories is briefly discussed in the DLS Strengths﻿ of this module with a deeper explanation provided by the Value﻿ section.
Common Characterics of Successful Applications
Additive material that meets the needs of the application
Temperature requirements
Chemical resistance
Biocompatibility needs
Mechanical properties
Business case (value) for utilizing additive
Design freedoms
Economic advantages
Part consolidation
Knowledgeable team 
A vision and/or inspiration on the value of using additive
Ability to design for the function of the part used in the application
Knowledge of the chosen application
Knowledge of the chosen additive process
Implementation strategy
Good relationships with customers 
(where customers are most likely a part of the team)
The following terms are used throughout this module. 
Additive Manufacturing - (3D printing) refers to a collection of technologies where materials are selectively accumulated to build, grow, or increase the mass of an object layer by layer until a three-dimensional object conforms to its digital model. Objects manufactured additively can be found throughout the product lifecycle, from pre-production ( e.g., rapid prototyping) to full-scale production ( e.g., rapid manufacturing) and tooling applications and post-production customization. ISO/ASTM 52900:2015 Additive Manufacturing General principles﻿
Application - function being performed
Component/Part - object manufactured to perform in the application
DLS™ (Digital Light Synthesis™) - A resin-based 3d printing technology utilizing CLIP, Carbon’s resins, and software to produce engineering-grade isotropic plastic parts with a good surface finish.
Manufacturability - as referred to in the presentation, encompasses the entire DLS process: digital prep (orientation & support), printing, cleaning (washing & support removal), baking (curing), and secondary operations (sanding/finishing).
Manufacturing method - a way to produce a part - any part whether it’s for prototyping, functional end-use testing, or true production. The manufacturing method could be modeling in clay, machining, molding, or additive manufacturing. Additive offers many tools for the manufacturing toolbox.
DLS Strengths
Additive manufacturing processes offer new options for producing parts. Understanding the value the chosen process brings to your part/application helps you know when to implement additive. This is similar to knowing how to choose between machining, injection molding, rotational molding, blow molding, extrusion, etc. Each of these processes has particular strengths depending on the application; they are all options in your manufacturing toolbox. Additive processes like DLS, SLS and FDM have recently joined well-established options like injection molding and machining in the manufacturing toolbox.
Additive manufacturing methods provide flexibility and design freedoms not possible from traditional methods. Use additive manufacturing strengths to drive value to your project, whether you are producing prototypes, production parts, or need a manufacturing solution. 
Each additive method has its own strengths. For example, Digital Light Synthesis (DLS™) combines the benefits of a liquid-based process with engineering-grade materials allowing your project to transition from prototyping to production utilizing the same manufacturing method.
To decide if DLS manufacturing is the right process for the application, one must understand it's strengths.
DLS Provides Needed Material Performance & Versatility
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DLS vs Injection Molding/Machining
Design Freedom
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Part Consolidation
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Economic Advantages
DLS can provide clear economic advantages in low volume production with no tooling costs or minimum buys to compensate for setting up tooling. There are further benefits to producing in low volumes by saving on inventory overhead.
DLS also offers a clear advantages when quick design iterations and turnaround is needed
Low Volume | Quick Iterations
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Economic Advantage Case Studies
Low Volume
﻿Fast Radius - Aptiv﻿
Low Volume
﻿Dinsmore - Biolase﻿
Quick Turnaround
﻿The Technology House - NASA﻿
DLS vs Additive Technologies
DLS offers distinct advantages when compared to other additive technologies.
Engineering grade materials: rigid and elastomeric
Watertight & airtight parts: no secondary operation required
Cosmetic surfaces
Fine features: Logos and labels, threads, textures
Watertight & Airtight | Fine Features | Cosmetic Surfaces
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Key Strength 
Carbon technology merges engineering grade material properties with all the advantages of additive manufacturing while utilizing the same manufacturing process and material from prototyping to production.
Evaluation Process
This easy-to-implement high level process uses 3 categories:
Material Specifications
Value
Manufacturability
Combining these categories with a few questions will help quickly identify good potential applications for the DLS manufacturing process. This method will also eliminate the unsuitable ones.
The Venn diagram is used to depict the relationship of the categories and how each one has dependencies on the others. The ideal DLS application meets criteria in all three categories.
Application Selection Venn Diagram
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This information was compiled from sales, engineers, and support functions that have served in the additive business for many years. Apply your own knowledge as well to tailor the method to your particular needs and create a starting point for application selection. Apply the method as a team or an individual, then once a good potential application has been identified, work with your team to make it successful. 
Material
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Know the Material Requirements
It all starts with the right material for the application. Incorrect material choice can doom a project for many reasons, from causing your part to fail or simply making the part too costly. 
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Carbon's Material Advantage
An advantage of the Carbon process is the ability to use the same material and process throughout the part's life cycle (prototype, production, end of life). During the prototyping process, the part's manufacturability can be honed and improved.
This is how MATERIALS overlap with VALUE (business case) of the evaluation process.
Value
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Define Advantage of Carbon
Engineering grade materials combined with the strengths of additive manufacturing.
Utilizing of the same material and process throughout the parts life cycle. (Prototyping, Production, End of Life).
All projects have to be justified. Therefore, once a suitable material has been identified, the next part of the evaluation process is a compelling business case.
For prototyping or a manufacturing jig, a business case may not always be a necessity, but walking through the value evaluation can lead to new ideas, showing what is possible with additive manufacturing and DLS technology.
When determining Value, answer this question: 
What is the business reason for utilizing additive manufacturing and DLS technology for this application?
Building a Compelling Business Case
This is about utilizing the strengths and economic advantages of additive manufacturing for the application in question. Is there an existing value for this project or can value be created (add a function or prevent an issue) by using the additive process that is not currently an option? Three large groups to categorize value criteria are:
Design Freedom | Part Consolidation | Econonomics
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The application in question might benefit from one or all three of these for a compelling business case. 
Design Freedom
Molds or toolpaths do not restrict DLS technology, unlocking unconstrained design freedom that allows designers/engineers to showcase unmoldable/challenging geometries. This provides the following design benefits:
Manufacture to the function of the application
Quicker iterations - no tooling or lengthy machine setups
More options/sizes for a part family or user-specific options
These benefits add value to your project and end part by improving part performance, reducing warranty, being on the market faster.
The design freedom provided by additive manufacturing allows the designer to implement different design strategies that are difficult to utilize with traditional manufacturing.

Let's explore some of those strategies.
1
Customization is an important strength of any additive manufacturing technology. Traditional manufacturing methods require new tools, which means more tools to manage, and/ or new machine setups. This can be a determinate to implementing customizations.
Some of the customizations that can be easily implemented with additive are:
User/Patient-specific parts
Application-specific parts
Logos
Part Numbers
Part with Logo | Part Number | Material
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This information can be placed into the native CAD file or in some cases added with the Printer UI. 
2
Textures can be aesthetic or functional like adding grip to a part. Textures can be molded but normally this a secondary operation to the mold. Depending on the texture it can be a costly add. With DLS technology it is added to the digital file.
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3
Lattices are impossible or extremely difficult to produce by other means. This design strategy opens up many product possibilities from light-weighting to designing for performance. 
Using Design Engine﻿, lattices can be built to performance specifications allowing for a variety of applications.
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4
Topology optimization creates some interesting structures that reduce material use and maximize part performance. Due to the organic nature of theses parts, they are not producible with conventional manufacturing methods. These structures are easily manufactured with DLS technology as seen in this example of a Carbon motor mount.
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Part Consolidation
Another strength of additive manufacturing is the ability to implement part consolidations. Consolidating assemblies can provide the following benefits with varying degrees of value for your project:
Simplify the product or the product use
Ability to add function to the part (aka - design the part for function)
Reduce points of failure like leak paths for sealing systems
Reduce assembly time
Eliminate hardware components such as screws and other fasteners
Eliminate tooling (molds, manufacturing jigs and fixtures, etc) for individual parts
Reduce cost of logistics for sourcing, storing, and shipping
Original Design
Individually molded parts = 3
O-rings = 2
Screws = 8
Assembly time required
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Designed for Carbon DLS
Individually printed parts = 1
Improved wire routing
All bullet points above
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Economics
The economics of the value evaluation is related to design freedom and part consolidation. If your part benefits from one or both of the other two, it will definitely have economic benefits.
Sometimes, the economic benefits of using additive manufacturing can prompt the designer to look more closely at the design freedoms. A good example is when an injection mold tool needs replacing, and it is determined that eliminating the tooling cost is business case enough to justify the project. By going back to the design freedoms of additive, the designer/engineer might add a new value that wasn't available with traditional means.
Three large economic advantage of the DLS technology:
Using the same material and process from the beginning to the end of a product lifecycle. This eliminates tooling cost, reduces testing iterations, and gets your product on the market faster. 
Ability to complete iterations - fast turn around time with minimum setup
Part quantity flexibility - No minimum buys - produce 5 to 10,000s in certain scenarios even higher, without minimum order quantities
This economic evaluation focuses heavily on the manufacturing economics of the part.
Eliminating Tooling
Reducing raw material or assembly part needs
Reducing shipping cost
Reducing warehouse storage
Eliminate minimum order buys
Specific factors that effect DLS manufacturing economics
1
When printing a production part - more parts on the platform increases yield with the same print time.
Example: 1 bracket = 2 hrs 12 mins vs. 22 brackets = 2 hrs 12 mins
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2
How long a print takes is affected by part size (Length x width x height) and material selection.
Part height increases printing time and the number of supports needed to stabilize the part.
The surface area (length x width) affects print time by how much time is needed to cure the current projection and heat build-up from that UV exposure.
Part Dimensions (mm)
20x20x20
20x20x80
90x90x20
Qty per Build
40
40
2
SOLID PART**
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RPU 70 Print Time*
0h 53m
3h 16m
1h 37m
EPU 46 Print Time*
0h 29m
1h 30m
0h 49m
LATTICED PART
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RPU 70 Print Time*
0h 41m
2h 16m
0h 41m
EPU 46 Print Time*
0h 24m
1h 18m
0h 24m
*Example only, subject to change based on printer improvements. 
**Large surface area solid shapes not recommended for printing. Used for demonstration only.
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Information is based on an M3 printer and is for reference only. Actual print times are variable based on part geometry and software version.
3
Support removal
Cleaning
Baking
These factors can be mitigated with design. Review the DLS Design Guidelines﻿ for tips and tricks.
Manufacturability
Manufacturability encompasses the entire process of physically producing a part.
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Print Prep
Printing
Post Processing
Washing
Baking (Thermal Curing)
Secondary Operations
Manufacturability evaluation is critical for the application/part's success. If the part can not be physically produced then another manufacturing method will have to be identified or research will need to be completed to figure out how to manufacture with DLSTM technology. 
Part design has a major impact on this evaluation. Utilize the recommended feature sizes from the DLS Design Guidelines﻿ and the design principles to evaluate the part for printing feasibility. The Design Guidelines provided recommended feature sizes, tips for designing parts without supports, and other pieces of information to help you design/evaluate a part for DLS.
Manufacturability Evaluation Process
Before evaluating printing feasibility, it is important to establish which Carbon printer best accommodates your application by assessing the available build volumes.
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1
How many parts can be built at once?
This is very important when assessing the feasibility of production runs or needing to produce a finite amount of parts in a quick amount of time. As shown before in manufacturing economics, the more parts per build, the better the economics (more parts in the same amount of time).
Part Size Guidance for Production Applications
Optimal size for the M2/M3 ~ 50 mm x 25 mm x 80 mm
About the since of a deck of playing cards
This allows ~20 parts per build
Ideal Part Size per Quantity per Build
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The DLS platform can certainly produce parts that are larger than a deck of cards! Some economic scenarios for larger parts are:
Prototyping
Replacement parts where tooling is no longer available and/or too expensive to create.
Reducing inventory and storage overhead with low-volume production runs.
Design is not possible with conventional manufacturing practices; DLS technology is the only option.
2
What is the printability of the part?
Now that it is determined, the part will fit in the build envelope, and quantity has been addressed. Look the part over for how well it will print. Use the recommended feature sizes and design principles to assist with this evaluation.
Design principles:
Consistent wall thickness
Gradual geometry changes
No trapped volumes
Self-supporting
Other items to look for:
Thin walls
Tall parts
Feature sizes
As you are evaluating the part, areas may be noted where slight improvements could really improve the manufacturability of the part. It is important to note those and discuss them with your customer. A very small change can be the difference between a part that is difficult to print vs. great.
Legacy 6-part design optimized to a single part
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3
How easily can the part be post-processed?
While the printability of the part is being assessed, also consider how the part will be post-processed (washed and cured). Similar items need to be addressed.
Design principles:
Consistent wall thickness
Gradual geometry changes
Cleanability
Support removal
Feature spacing to allow the resin to be removed by solvent
Other items to look for:
Thin walls
Sharp corners
Drastic change in geometry
Many of these items can be addressed with design and the changes you make to improve printability will improve the post-processing and vice versa. As would be done with printability, note where changes could improve the post-processing to discuss with your customer. This can greatly improve the part's manufacturability.
For example, the part shown here has several defects from print errors and post-processing problems that are all resolvable with slight design changes.
Post-processing problems:
Thin walls warped during the bake
Unvented volumes caused resin removal issues
Salt is stuck to part
Poor design updated for easy post-processing
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Value and the manufacturability of a part are heavily influenced by the design of the part. The manufacturing economics are discussed during the value evaluation because it affects the business case. These interdependencies are how value and manufacturability are related.
Applying the Method
The following is an exercise in applying the Application Selection evaluation method. 
Example Project Requirements
The company is a leading battery-powered zero-emission bus producer that creates unique vehicle configurations to meet local requirements. The part is an ergonomic door switch handle. The typical order quantity for each bus configuration is 2 to 25. Each bus has approximately 4,000 different parts.
Part Information
Quantity needed = 10
Tooling cost ~$25,000
Customer Bonus 
If possible can this handle be used as a handle to access different panels on the bus?
Ergonomic door switch handle
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Material Requirements
Temperature requirements
No extreme temperatures - 0 - 65° C
Chemical resistance requirements
Basic chemical resistance needed
No extreme resistance required. No submersion in any chemical or other types of long-term exposure.
Biocompatibility
None
Mechanical properties
Needs to withstand general impacts, in case items are dropped on it, etc
Stiff enough to withstand hand torque
Example Project Assessment
Use these printable handouts to assist you with this exercise and ask yourself these questions in each category as you go.
DLS Application Selection Quick Guide
App-Selection-Quick-Guide-v0150.pdf
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DLS Application Selection Worksheet
App-Selection_Worksheet_English_v0200.pdf
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App-Selection_Worksheet_Italian-Italiano_v101.pdf
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Material Specifications
Should this material be a rigid or elastomeric material?
What is the right material for this application?
Value
What is the business case for utilizing additive to produce this part?
What are the DLS strengths that can be utilized?
Each column will not always have an answer.
Manufacturability
Can this part be physically produced with DLS technology?
Example Project Conclusion
By applying the application method, it is clear this is a good fit for Carbon DLS. 
There is a material that fits the needs of the application.
Design freedom can be utilized to add function to the part (a texture for grip) and to design the part in such a way it can be used for multiple functions.
Great low volume manufacturing economics.
The part is physically manufacturable with the M2 or M3 printer.
Electric Bus Components
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Compelling Business Case
Material Specifications
RPU 70 met needed requirements
Value
Design Freedom
Manufacturing Economics
Low volume - 2 to 25 of each part
Part Description
The Challenge
The Solution
﻿Proterra is a leader in the design and manufacture of zero-emission electric transit vehicles and EV technology solutions for commercial applications. Since 2004, Proterra technology has been proven through more than 18 million service miles in heavy-duty applications. 
This company needed low volume, high quality, production parts.
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This part incorporates multiple criteria from two of the evaluation categories of the application selection process. It highlights an example when larger parts are economical for the M2/M3 platform. Read the full Proterra Case Study explaining how Carbon met the low volume needs of this manufacturer.
With products built to order volumes range from 2 to 25 vehicles. An average Proterra vehicle has about 4,000 different parts, each of which can require different materials and manufacturing methods. A sizable portion of these parts are injection-molded plastic parts, and managing thousands of these parts through their entire lifecycle is an enormous task. 
Low volumes result in the injection-molded components to be expensive!
Challenges:
Tooling cost
Inventory management
Molds
Parts
Utilize DLS Technology
Material that meets the needs of the applications, RPU 70
High-quality surface finish
Ability to produce on-demand the needed quantities
Ability to iterate quickly and met production schedules
Two parts were chosen for production on the M2 platform.
Ergonomic Dual Purpose Handle
Able to use the design freedom to make this a dual purpose handle for a door switch and a functional tool handle for access panels
Added a texture for better grip
Large (318 x 110 x 40 mm) Customized Dash Plate
Cost reduction from traditional methods
Better surface quality than the previous family of parts
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Example Case Studies
See how this selection method works for other successful applications from across industries. 
Vitamix Rinsing Nozzle
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Compelling Business Case
Material Specifications
RPU 70 met all needed requirements
Value
Part Consolidation
Design Freedom
Manufacturing Economics
Manufacturability
Design freedom allowed the part to be fully optimized for the process with minimized supports and improved cleanability.
Part Description
The Challenge
The Solution
﻿Vitamix is a market leader in blending technology for consumer and foodservice commercial markets. These blenders are used across the United States in coffee houses and other foodservice markets.
Vitamix was looking to produce a durable microfluidic nozzle to rinse their commercial blender container to make cleaning more automatic and remove the manual labor for the coffee house.
Vitamix Rinse-o-Matic Full Assembly
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Traditional injection molding design used 6 parts and was assembled
Ability of the part to handle daily wear and tear in a commercial food service environment
Material had to perform in environments with high-pressure water, bleach, and other sanitizers
Short timeline
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A newly designed single part that requires no tooling or assembly.
10x more durable than previous designs - Passes 1.5 million rinse cycles in the field
Part uses 30% less material.
Part is 33% more economical.
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Engineers at Vitamix and The Technology House, a Carbon Production Partner, worked together to solve the challenges of this part and optimize it for the DLS technology.
This part incorporates multiple criteria from all three evaluation categories of the application selection process. For the full Vitamix Case Study and a video visit the Carbon Website.
Medical Equipment Component
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Compelling Business Case
Material Specifications
MPU 100 met all needed requirements
Value
Design Freedom
Manufacturing Economics
Manufacturability
Design freedom allowed the part to be fully optimized for the process.
Part Description
The Challenge
The Solution
﻿Becton, Dickinson and Company (BD) built a next-generation cell-level genomic analyzer used to understand cellular form and function on the basis of individual cells. This information is used in medical fields such as immunology and oncology. One of the key components is the hemocytometer adapter that integrates a fluidic microwell component into an optical system. 
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Traditional manufacturing had too many limitations and additive manufacturing was chosen as a potential solution. The right additive process had to deliver cost and speed benefits without compromising the part's design requirements.
Key design requirements
Sliding surfaces
Central slide holder for fluid analysis
High quality surface finish
Challenging features:
Trapped negative space 
Undercut structures
Window for optics
Utilize DLS technology: 
Material that meets the needs of the application, MPU 100
Design freedoms over traditional manufacturing and other additive technologies
High-quality surface finish
Engineers from BD and Carbon worked together to:
Optimize the part for the process
Rotated grid by 45° to allow direct on platform printing
Eliminated need for supports improving post-processing and reducing labor
Integrate a texture on the hero surface to improve aesthetics and functionality
The result was a cost-effective part with improved functionality and meet the project timelines.
By optimizing the part for the DLS process:
Print time was reduced by 55%
7% less material usage
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This part incorporates multiple criteria from all three evaluation categories of the application selection process. It is also a great example of part optimization for the DLS process. For the full BD Case Study that walks through the design changes made visit the Carbon Website.
Aptiv™ Dust Cap
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Compelling Business Case
Material Specifications
FPU 50 met needed requirements
Value
Design Freedom
Manufacturing Economics
Part Description
The Challenge
The Solution
Aptiv is a global technology company providing electrical and fiber optic connection solutions for ocean travel, including commercial and military vessels. 
Aptiv offers fiber-optic connection systems, including connectors, termini, and cable assemblies suitable for ocean-faring vessels as part of a connected solution. When docked in a harbor or with another ship, a ship can use these cables to transfer sensor data rapidly. The fiber optic interior must be completely insulated from the harsh conditions outside, including saltwater, fungal life, impact from the ship moving, and, critically, dust. Each cable is outfitted with a dust cap to prevent dust from interrupting the fiber-to-fiber connection
This company needed a lighter weight, easier to produce, and cheaper solution.
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Historical solutions are predominantly stainless steel or plated aluminum requiring intense post-processing to meet functional and environmental criteria. These are expensive to produce and heavy. 
Injection-molded polymer solutions were two parts and could not pass the quality tests.
Challenges:
Strict qualification criteria
Impact resistance
Sand and dust exposure
Fungal resistance
Salt spray resistance
Design requirements
Threaded part
Undercuts
Tight tolerances requiring part precision and repeatability
DLS technology was able to provide a material that met all requirements including 2 military-grade standards and a part that was lighter weight and more economical to produce. 
FPU 50 passed 6 strict qualification tests
Impact
Sand + Dust Exposure
Engagement/Disengagement Torque (Military Standard)
ID Marking (Military Standard)
Salt Spray Testing
Fungus Resistance
Precision and repeatability for the threads
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This part incorporates multiple criteria from two of the evaluation categories of the application selection process. It highlights an example when the engineering-grade material performance was a key contributor to the success of the part. The economic advantages of additive manufacturing were important but the right material needed to be available. That material was found in FPU 50. For the full Aptiv Dust Cap Case Study explaining how Carbon met the low volume needs of this manufacturer visit the Carbon Website.
Note that it is not always necessary to have an application that falls into all 3 evaluation criteria and that meeting 2 of the criteria is enough for a successful project.
Uncompelling Business Cases
It is critical to use the manufacturing method that best fits the needs of the component and DLS technology is not always the best fit. Here are some scenarios when DLS technology is not the best fit for production. 
Locked designs
Designing for the process is the key to success
If a part is designed for CNC machining, it would need some design changes to produce by injection molding. 
Manufacturing with DLS technology is no different, design changes will be needed to change over to this process.
Long/tall, thin parts
Parts less than 1.5 mm thick
Parts that DO NOT meet any of the Recommended Features Sizes﻿﻿
Parts easily produced by other methods
Injection Molding | Machining | Die Cutting | Thermoforming
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Application Fit Summary
The Carbon platform is a proven manufacturing technology that offers a flexible process for quantities with design freedoms not possible from traditional methods. Part design plays an important role in the success of your part/component. Combine design and Application Selection knowledge to create successful parts. 
DLS Strengths
Keep the strengths of DLS in mind when evaluating a particular application:
DLS vs Traditional Methods (machining, injection molding, etc.)
Unconstrained design freedom (textures, lattices, etc.)
Part consolidation (fewer points of failure, etc.)
Easy to implement iterations (no tooling)
Economic advantages (low volume, reduce time to market)
DLS vs Additive Technologies
Engineering grade materials (rigid and elastomeric)
Watertight and airtight materials
Cosmetic surfaces
Fine features (logos, threads, textures)
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Part Dimensions (mm)	20x20x20	20x20x80	90x90x20
Qty per Build	40	40	2
SOLID PART**
RPU 70 Print Time*	0h 53m	3h 16m	1h 37m
EPU 46 Print Time*	0h 29m	1h 30m	0h 49m
LATTICED PART
RPU 70 Print Time*	0h 41m	2h 16m	0h 41m
EPU 46 Print Time*	0h 24m	1h 18m	0h 24m
Updated 27 Feb 2025
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DLS Design Guidelines
Application Selection

What Makes a Successful Application

Glossary

DLS Strengths

DLS vs Injection Molding/Machining

Design Freedom

Part Consolidation

Economic Advantages

DLS vs Additive Technologies

Evaluation Process

Material

Value

Manufacturability

Applying the Method

Example Project Requirements

Example Project Assessment

Example Project Conclusion

Example Case Studies

Vitamix Rinsing Nozzle

Medical Equipment Component

Aptiv™ Dust Cap

Uncompelling Business Cases

Application Fit Summary
