Process Overview

introduction all manufacturing processes involve following a series of steps to create final parts, and digital light synthesis™ follows the same approach view the following video for a summary of the process of producing parts with carbon's dls technology video text pre print digital prep select a printer from the dashboard click new project and import an stl file select a resin orient the part add support (if needed) layout the build platform run project analysis add to print queue click print ready for printing! resin dispensing two part check cassette install mixing tip per resin protocol install cartridge in dispenser burn off resin per protocol disense required resin amount at protocol speed printing m2 printer open door using footswitch install cassette with resin lock cassette latch install clean platform verify seated properly close door verify the correct project queued to the printer press start print open door when the print completes remove platform place on transfer tray to collect drips close door post processing washing manual washing fill washtub with protocol solvent 75% of part height place parts in washtub and close lid turn on orbital shaker and wash parts at rpm and solvent exposure time remove parts from washtub dry with compressed air or air dry smart part washer part washer basket available adapter for m3 platform not compatible with l1 platform select start wash default (or an alternative cycle) wash begins dry with compressed air or air dry part removal hold the platform press the blade flat against the platform remove the parts from the platform remove supports lightly damped swab touch up the parts curing preparing parts for baking baking trays oven place tray in oven start the oven following the curing protocol remove part(s) from the oven part(s) ready for use process outline pre print 1\ print prep use a computer to access the printer ui orient, support and arrange digital models 2\ resin dispensing mix resin and fill printer cassette with the amount required for printing print process 3\ printing the automated process where the printer creates parts by using uv light to solidify the liquid resin post processing 4\ part removal printed parts need to be removed from the platform either before or after washing 5\ washing liquid resin is removed from parts by rinsing with solvent or by spinning 6\ curing (baking) parts achieve their final mechanical properties through the application of uv light (one part resins) or heat (two part resins) always reference resin specific page and protocols for detailed information of each step information can also be found in the docid\ ujf4k0ny4lye74zohx1r printer features all printers have common features the information below focuses on 3 features the build area, platform and cassette see a brief description of these below the printer pictured below is an m3 max, but these features apply to all carbon printers build area the main functional space of the printer where parts are printed operators will primarily interact with components in this part of the printer during daily operation the major components of the build area are platform cassette platform the platform is a removable appliance with a flat surface upon which parts are printed platforms are larger or smaller depending on the printer type cassette the cassette is a highly engineered optical device that is a critical component of the digital light synthesis™ platform it is a removable appliance that holds the liquid resin used to make parts the window must be properly maintained to ensure print quality improper maintenance or damage to the window will reduce print quality and may result in failed prints and production delays follow the links below to learn more about printers and cassette maintenance docid 6pwz7jx jb4l5 xwkoj docid 3yymggihdvaowg01eay6l docid\ on8otjugbxoth6qmqw2om docid\ y imi7aevlyjbsatexxdb handouts dls process overview handout quick reference document showing the workflow steps lab reference grids this printable handout is vital for printer technicians and provides information about resin storage and dispensing, washing times and compatible solvents as well as cure times make sure to always have a copy available english german/deutsch spanish/español japanese/日本語 dental post processing grids one of our most popular downloads! this table provides washing and curing instructions for all supported dental resins print it and use it in the lab as a quick reference images of dental post processing grids english german/deutsch spanish/español print prep before printing parts, project preparation is necessary, known as print prep this involves importing an stl file into the printer's user interface (ui), accessed via a web browser on a computer, which controls the selected printer to create a project for printing, follow the steps below video text select a printer from the dashboard click new project and import an stl file select a resin orient the part add supports (if needed) layout the build platform optional adjustments scale parts part labels print controls run project analysis review unvented volumes check slices review islands add to print queue click print note about "click print" this action only sends the project to the printer it does not start the printer the print only begins once an operator starts the print at the printer or on the pop up window that appears after clicking print when setting up a build in the printer ui, start on the left and work your way to the right after importing your part, begin by selecting a material on the left then work from left to right on the top bar of the ui finishing on the right of the screen with print resin mixing and dispensing resin must be added to the cassette before printing can begin one part resins can quickly agitated and poured two part resins require more precise mixing with additional equipment cartridges are dispensed by using an electric dispenser and mixing tip bulk materials are mixed and dispensed with a range of equipment including vortext, overhead and planetary mixers dispensing one part resins check the cassette the window should be clean and free of damage invert the one part resin bottle 5 6 times to distribute the pigment pour the required resin amount into the cassette this amount is provided in print analysis after the build is complete, the resin can be reused, discarded, or saved for later use additional information docid 4lwk3k36rfqf2raovxszx includes information for dispensing two part resins printing for specific hardware operating instructions, refer to the correct hardware course open the printer door install the cassette m series cassettes will contain the dispensed resin l1 printers, the resin will be poured into the cassette once installed inspect the printer platform be sure the platform is clean and damage free install the platform close the print door for m series printers for l1 printers, the door closes when the print begins verify the correct project is queued to the printer start the print see various options in specific hardware courses when the print completes, open the door remove the platform close printer door additional information docid 6pwz7jx jb4l5 xwkoj docid 3yymggihdvaowg01eay6l docid\ on8otjugbxoth6qmqw2om docid\ y imi7aevlyjbsatexxdb washing there are two options for washing manual automated manual washing parts washed manually can be washed on platform or off platform consult the lab reference grid or the resin protocol for specific process information such as solvent and solvent exposure time fill a washtub to 75% of the part height place washtub on orbital shaker use the magnets to hold the washtub in place place part(s) in washtub and secure the lid set the orbital shaker to the rpm specified for the resin turn on the shaker and wash for the specified time remove parts from the washtub air dry or dry with compressed air or spinner check the parts sometimes touch up cleaning is necessary refer to the basic washing course for touchup methods washing parts on the platform is shown here parts can also be removed from the platform before washing tips for washing two part resins always wash parts within the pot life of the resin for best results, wash as soon as possible after print completion parts do not achieve final strength until bake in convection oven handle with care automated washing other equipment can be used to remove liquid resin from parts purpose built washing machines like carbon's docid\ hvgvbthckek4hxjqqfpo , the docid\ uqieq5peg3cklftphtl3o and the docid 93lfgiaqg51aw2hhu080g use solvents to wash parts parts can also be spinned clean using the industrial strength heinzen spinner or smaller devices spinning can be especially useful for latticed elastomer parts which are sensitive to solvent overexposure the smart part washer provides an automated solution that washes parts on the platform when the completed build is placed in the smart part washer, this connected device detects the build information and provides a wash cycle for that build install the platform in the smart part washer select the preferred wash cycle the lid closes and cycle begins when the cycle completes, the lid raises remove the platform from the washer if using dpm solvent, dunk parts in ipa 10 times over 10 seconds air dry or dry with compressed air check the parts sometimes touch up cleaning is necessary refer to the basic washing course for touchup methods each resin has a maximum solvent exposure time overexposing parts to solvent will adversely affect material properties see the protocol sheet for your resin for maximum solvent exposure time additional information docid\ avn2rnslshhmuz9rbykmn docid\ hvgvbthckek4hxjqqfpo docid\ ujf4k0ny4lye74zohx1r docid\ uqieq5peg3cklftphtl3o docid 93lfgiaqg51aw2hhu080g part removal parts need to be removed from the platform before curing this may happen before or after washing, depending on your needs washing parts on the platform can be benificial if parts are delicate or preserving surface quality is especially important the platform holds the parts in place during washing, preventing surface abrasion or damage to delicate features removing parts from the platform before washing requires less solvent however, this is recommended for parts printed in tougher resins or where surface finish is less important as parts will bump into each other during washing some materials and geometries can be more challenging to remove than others for example, elastomeric lattices may require more care than solid rigid parts 1\ make sure the platform is stable on a work surface 2 hold the platform against the work surface 3 press the scraper blade firmly against the platform always aim away from you 4 use the scraper to apply a slow steady force on the part(s) to detach from the platform 5\ remove supports from the part(s) touch up the part(s) if needed 6 clean the platform see the hardware (m1/m2, l1, m3) course for information curing curing sets the final mechanical properties and makes the parts safe to handle without gloves the type of curing utilized will be dictated by the resin one part resins cure with uv (ultraviolet) light completes the curing process started during printing two part resins cure with heat (typically called thermal curing or baking) activates a secondary chemical reaction that finalizes the mechanical properties creating engineering grade material properties uv curing most uv ovens project light from the top down only surfaces that are struck by light are cured undersides of parts or areas that are in shadow are not cured each part will need to be rotated until all surfaces have been exposed to the uv light be sure the parts are clean and dry all supports are removed no unwanted resin surfaces are dry arrange the parts in the uv oven uv cure each side of the parts according to the lab reference grid remove the parts from the uv oven with clean gloves parts are ready for use! thermal cure (baking) thermal curing is accomplished by baking parts in a convection oven each two part resin has a specific curing program with custom timings, ramps and temperatures some variations of thermal curing include docid\ whftudzdy0cs0a0 dljcm and docid\ hukhdkofw9hthse0dd8ly be sure the parts are clean and dry all supports are removed no unwanted resin surfaces are dry inspect any baking implements (baking sheets, mesh, fixtures, etc ) that will be used these should be clean prepare the chosen baking implements setup parts with baking implements or fixtures place in the oven bake according to thermal curing requirements parts can be cooled inside or outside of the oven a recommended cooling procedure is on the lab reference grid remove parts from the oven using heat resistance gloves, if not cooling completely in the oven remove parts from all baking implements (sheets, fixtures, salt) if salt packing was used, the salt needs to be removed from the part parts are ready for use! bakingsalt baking additional information docid\ l nks7czuarr vheuozgp docid 7ne6rgdaszpapohh5qozm docid\ whftudzdy0cs0a0 dljcm docid\ hukhdkofw9hthse0dd8ly