The advantages of 3D printing technology are obvious relative to injection molding. Especially for small batches with complex geometries, 3D printing is by far the simplest and most cost effective solution. The only thing that can be matched with injection molded products is its surface quality and structural properties. But today, this advantage of injection molding technology may not be fast.
Recently, a group of researchers from the Technical University of Vienna (TU Wien) in Austria developed a new type of 3D printer that can directly print high-viscosity polymers originally used in injection molding equipment and light treatment of DLP 3D printers. Laser-accurate SLA techniques are combined to optimize the surface quality of printed objects.
It is understood that this new 3D printing solution was developed by a team led by Professor Jürgen Stampfl. Professor Stampfl specializes in the development of new materials and corresponding 3D printers. The team has been looking for ways to use high quality plastic materials more efficiently for 3D printing to improve the surface quality and mechanical properties of 3D printed parts. They believe that this is the key to the ongoing 3D manufacturing revolution. The study was also funded by the EU Horizon 2020 program (project number 633192 (ToMax)).
In particular, they have been focusing on the research of polymers with high viscosity, impact resistance and excellent surface quality, which is lacking in current 3D printing technology. With a new 3D printing technology based on DLP (Digital Light Processing), they are finally able to take advantage of these materials. It is reported that this team of Austrian scientists has created a 3D printer that relies on DLP light sources. Unlike ordinary single-waves that rely on a single light wave to harden the entire 3D object, this device combines a DLP source with a precision laser (usually used on SLA 3D printers) to greatly increase print resolution.
More importantly, this new 3D printing solution can support a wide variety of materials. 3D printers based on DLP or SLA technology often rely on inelastic thermosets such as (meth) acrylates and epoxy compounds, and Austrian scientists have improved their resin systems to accommodate a wider range of Polymers, including those with high viscosity and good impact strength. This is the first time that a 3D printing system can use these polymers that have been monopolized by injection molding. In addition, the design supports a wide range of ceramic materials such as alumina, zirconia, bioglass and tricalcium phosphate.
This paved the way for a wide variety of innovations. Researchers believe that the thermal performance of the components printed on the 3D printer will be superior to that of the molded parts. In addition, they can perform 3D printing at high resolutions of less than 20 microns, resulting in 3D objects with a wall thickness of only 0.1 mm. In addition, the new 3D printer (prototype) they developed has a maximum build size of 144 x 90 x 160 mm. “It can be used to produce high-strength components with high elongation at break, as well as rubber-like components (such as shock absorbers). Compared to conventional SLA materials, it has an impact strength of 40kJ/ M2, elongation at break is 40%, and heat resistance is greatly improved," the researchers said.
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