US 3D printer manufacturer Carbon is partnering with Covestro to produce its polyurethane liquid resin. This resin allows objects to be printed using light and oxygen, enabling 100 times faster printing than Selective Laser Sintering (SLS).
Carbon has developed a 3D printing technology called Digital Light Synthesis (DLS). This technique uses ultraviolet light to cure the special resin Carbon has developed. By exposing the resin to this light in specific areas, it is possible to create an object from the resin. During this process, air is supplied from below through a membrane. This process counteracts the curing of the object on the underside, allowing the object to be pulled up continuously during printing without individual layers deforming.
M2 and M2d
The US company offers several 3D printers: the M2, M2d and L1 printer. The M2 is the successor to the M1, the first model launched by Carbon. This new version can print objects of up to 18.9 cm by 11.8 cm by 32.6 cm using Carbon's DLS technology, with a resolution of 75 µm. With the M2, Carbon aims to deliver a 3D printer suitable for any application.
A special version of the M2 is also available for dentistry: the M2d. This printer was developed specifically for printing dental implants. The M2d offers the same features and print quality as the M2, but features a smaller print bed.
L1 for large volumes
The L1 is Carbon's latest model of 3D printer. This printer is specifically aimed at high-volume production. The L1 can print objects about five times larger than those that can be printed with the M2. Although Carbon does not mention specific dimensions, this would mean that objects of around 94.5 cm by 59 cm by 163 cm could be printed.
Carbon points out that companies like adidas and Riddell are deploying the L1 to print millions of objects. For example, adidas deploys the technology to produce its FutureCraft 4D shoes. Targeted at athletes, these shoes are customised to meet athletes' specific needs for freedom of movement, cushioning, stability and comfort. The use of 3D printing technology allows each shoe to be tailored to its user.
Smart Part Washer
Products printed with Carbon's 3D printers can be post-processed in the company's Smart Part Washer. This system is designed to clean 3D-printed objects with minimal manual handling. In doing so, the system helps reduce the cost per part.
Carbon is now partnering with Covestro to scale up production of the polyurethane liquid resin its printers use. "Our biggest challenge in scaling up additive manufacturing to production runs lies in the availability of suitable materials in the required quality and quantity," explains Patrick Rosso, head of additive manufacturing at Covestro. "By partnering with companies like Carbon, we are pushing the current limits of scalability and supporting various industries in the value chain on their way to digital mass production."
Covestro will research new materials suitable for a wider range of applications. For this research, the company's 3D printing laboratories in Leverkusen, Germany, Pittsburgh, USA and Shanghai, China, will be revamped. In these labs, materials for high-volume additive manufacturing are developed and tested in collaboration with customers.
Author: Wouter Hoeffnagel
