The Lightforge 3D Printer

Lightforge is developing a personal resin-based 3D printer, a device that apparently doesn’t have an official name yet. We checked out the machine, which was actually a “version 1 prototype”, built after some fifteen months of development. 

 

A spokesperson indicated they’re currently working on a version 2 prototype that may be part of a Kickstarter campaign expected in a couple of months. 

 

The machine uses DLP UV light to solidify photo-curable resin, much like several other resin-based devices do. Because the DLP tech enables curing of an entire layer at once, the unnamed Lightforge machine could be faster to print than laser-based devices in which the laser must ponderously trace each solid area of every layer. This means you could print a cube the size of the entire (large) build chamber in about 6.5 hours. 

 

The machine features a unique peeling mechanism. The company has obtained a “Patent Pending” on this new design. 

 

Other features include the ability to store models in the printer for offline production. Future versions of the machine will include network connectivity. They’re also making arrangements with NetFabb to produce customized slicing software. 

 

While they’re producing their own resins, it sounds like they will also permit “open resins” to be used in the device. However, Lightforge is developing multiple resins, including polyurethane and polyester types. 

 

The price of the unnamed Lightforge machine is unknown, but we’re expecting to see a price somewhere between USD$2-3,000, probably at the USD$2,500 mark. But you should pay attention to their Kickstarter campaign when it launches, as they may offer early bird special discounts. 

 

Via Lightforge

The Rise of Resin 3D Printers

There was something quite unusual about the 3D printer manufacturers exhibiting at CES 2014 versus those exhibiting the previous year. At the London 3D Printshow, for example, we saw dozens of plastic filament machines, typically regionally focused. 

 

At CES 2014 we saw multiple resin-based 3D printers. It seems that the expiration of patents has permitted the emergence of new ventures specifically focused on exploiting the UV-cured resin approach. 

 

Previously the only personal 3D printer entrant producing a resin-based unit was Formlabs, who launched the Form 1 over a year ago. But last week we saw units from Old World Laboratories, Lightforge and FSL3D, all of which use cured resin technology. 

 

These vendors all claimed various advantages over Formlabs’ offerings, citing statistics and specifications of various sorts. While this may appear to be huge competition for Formlabs, they don’t seem to think so. Formlabs reps we spoke with said the presence of resin-based competitors simply validates their business model and they’re quite happy to compete with them.  

 

We think the competition is a good thing; it’s rarely a happy time when one vendor has a monopoly and that’s definitely not happening in the 3D resin printer market. 

 

Watch out for the machines with the orange lids. 

 

The Kevvox 3D Printer

We had a close look at the Kevvox 3D printer at EuroMold. It uses a resin-based process, as so many new 3D printers seem to these days, but the results are quite spectacular. 

 

Three years in development, the Kevvox uses long-lasting LED lighting to cure the several resins offered. They offer a wax resin for casting, an ABS-like resin and a high-temperature-capable resin. Two models are offered with differing build volumes and resolutions: 

 

• Kevvox SP4300, 56 x 35 x 100mm 0.043mm resolution
• Kevvox SP6200, 80 x 50 x 100mm 0.062mm resolution

 

The larger is priced at USD$25,500, while the smaller unit goes for USD$21,500. So far, Kevvox tells us they've sold "hundreds" of them. 

 

What got to us was the incredible detail on the prints, as you can see here. This fellow, for example, is only 80mm tall. Click on the image to see the full level of detail. 

 

If you need this level of resolution, you might want to check out Singapore-based Kevvox. 

 

Via Kevvox

The Asiga Pico 3D Printer

We're starting to observe a collision between the lowering prices of commercial 3D print gear with the rising prices of increasingly more capable personal 3D printers. Today only a few thousand dollars separate the two. One example of a commercial unit that's priced very effectively is the Asiga Pico, a small volume resin-based 3D printer. 

 

The coffee maker-sized Pico uses UV light to cure a resin into solid shapes. While you can get the same type of technology from other manufacturers, the Pico is definitely small volume: several models have build volumes ranging from 30 x 40 x 76mm to 35 x 22 x 76mm. That's quite small, but oh, what you can do with it!

 

The resolution on the Pico is incredibly accurate with layer sizes in the one micron range. That's 0.001mm. Tiny! It's possible to produce the most delicate small objects. 

 

Typically the machine is used for producing wax prints for metal casting. In other words, Jewelry. 

 

Asiga also provides a plastic resin and another suitable for medical use. 

 

One very interesting feature is a special teflon "membrane separation" process that permits printed objects to be removed from the bed with "almost no force". This means that objects can be especially delicate, where they would not survive extraction on other resin machines. 

 

The price for this, you ask? Only USD$6,990. Not much more than a couple of MakerBots. 

 

Via Asiga

Prodways' Unique 3D Printing Process

It's always interesting to examine a 3D printer with an entirely new process for producing objects. One may think there's only a few processes, but in fact companies often invent new methods. 

 

Prodways is one of them. 

 

We spoke with Prodways President Raphaël Gorgé (seen above with the M350) and Head of Research & Development André-Luc Allanic to learn more. 

 

Prodways uses a resin process, similar to other manufacturers, but there's a huge difference. 

 

Resin 3D printers use photo-curable liquid resin, often solidified by a moving laser light. Sometimes a DLP projector is used, where a complete array of 1024 x 768 "pixels" is solidified in one shot. With the DLP approach you can focus the array on a small area to produce objects with super-fine accuracy (but only 1024 x 768 resolution). Such systems are lousy at making large objects because the resolution worsens as the same DLP array is simply focused on a larger layer area. 

 

Prodways changes all that. They use a DLP approach, but instead of shooting the entire layer with the photo array, they can do it multiple times. 

 

They MOVE the DLP array across the resin surface, enabling the production of super-fine objects at massive size. How massive, you ask? Their M350 Producer unit can print parts with "diagonals greater than 1 meter and up to 550 mm high". Whoa. 

 

And how fine can the resolution be? Let's put it this way: they can print 100 swatches of 2 million pixels each on each layer. Of course, if you have an object that doesn't occupy the entire layer, only the required portions are illuminated, significantly speeding up the printing process. 

 

The print volume and resolution combined are so huge that the this machine has actually printed STL files exceeding 8 Gigabytes in size!

 

Even better, Prodways has dedicated chemistry staff that are busily designing new resins, including ceramic resin. If you can afford it, you can purchase several resin tanks - and quickly swap them in/out to almost instantly change materials. No need to empty and refill the reservoir. 

 

You might expect this machine to be expensive, and you'd be correct. The M350 Producer is priced at €350,000 (USD$480,000). So far, we're told, 15 units have been sold. 

 

Via Prodways

Formlabs Releases a New Resin

Formlabs, makers of the popular Form 1 personal 3D printer have released a new resin. Previously, the company offered only two resins: Grey and Clear. The new material is "White". 

 

For a rapid startup company such as Formlabs, it's totally understandable they may take some time before introducing new materials, but now they've done it. 

 

Different resin formulations can produce all manner of material outputs, exhibiting different colors, strengths, temperature endurances, surface textures and other characteristics. We've observed larger, commercial resin-based 3D printer companies spend considerable effort on resin formulations - even hiring their own teams of chemists. We're hoping the release of "White" means Formlabs now has significant chemical expertise on staff. 

 

As for "white", we are very excited because it's our belief that the color white is often the best color to print. Why? Because its light color easily shows off shadows, exhibiting the delicate printed shape in the best way possible. 

 

White resin is available at Formlabs' online store for USD$149 per liter. 

 

Via Formlabs