Reify-3D Solus DLP Printer

[Reify 3D]

A free solution is to provide a print file specific for the popular printers that the customer can print on their own, this way it doesn't have to be a "one size fits all" product.

That's an interesting idea. If our print area was larger people could use Solus to print their own projector mount.


Currently, we're discussing adding a simple projector "sled" that is attached to the base plate with one or two rails. Similar to the rip fence design on a circular saw. This should keep build and shipping costs low so that it is still a very affordable printer for research applications.

[chekming1225]

I see the picture show that, the projector emits beams of light to a mirror. The light travel 90 degree to the resin tank. How would this be calibrated to get a shape, non-distorted image onto the resin take base?

Will this method better than SLA laser light source?

[Reify 3D]

They both have their advantages and disadvantages.

Consumer laser-based SLA printers usually have a laser with a dot size of around 300 microns so this is the smallest feature size you will be able to print. But because of their mirror galvo system they are able to move the laser in a straight line, usually in about 1 micron steps. DLP printers are able to offer XY resolutions often well below 100 or even 50 microns but the image is made up of an array of square pixels (or sometimes diamond pixels depending on the DLP chip pixel orientation).

The galvos used in most lower cost printers are quite affordable at around 100 USD on Aliexpress. I know the new Form1+ has an upgraded laser so it should cost more, but still likely much cheaper than a DLP projector.

Laser-based printers are often much slower as they need to draw the whole print layer one line at a time. DLP printers can project a whole layer at a single time so if you are printing large, multiple or complex objects the time difference can be very significant.

Whereas the XY resolution for most DLP printers is dependent on the build area (except something like a Prodways' printer which has a moving light engine), it doesn't matter for SLA printers. But if you print near the outside of build area the laser dot won't be circular anymore due to the angle at which the beam intersects the build plane. Imagine shining a flashlight on a wall and directing the beam sideways.

There are likely more pros and cons I'm forgetting, but I think I've listed the basics.

To calibrate Solus we project a grid and calibration object onto the build plane and adjust the mirror until the grid is rectangular. We then measure the object image to calculate the XY scaling. If you need highly accurate prints then it is best to print the calibration object in opposite corners of the build area and measure them and adjust your scaling and mirror alignment as necessary. This also helps compensate for any resin shrinkage. It sounds complex, but it only takes a few minutes once you learn the process.

[Reify 3D]

Here are a couple of examples of the detail we can achieve printing at 25 microns XY and 20 Z. They were both designed by Jewels Cottage from Delhi, India.

The raised features on the earring are about 100 microns and the channels are about 200 microns. The holes in the center of the smaller braiding are 100 microns and 125 on the outer braiding.


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[Reify 3D]

Just a quick update for anybody who's interested. We've spent the last couple months working hard on a new printer that eliminates the earlier concerns of an unmounted projector and open mirror. It will also have a much smaller footprint and improved speed. I just printed a 28mm miniature with MakerJuice SF sliced at 25 microns Z with a speed of 700 layers/hour.

We are not quite ready to release it yet but here's a test print of its XY resolution.

[sitio]

very very nice info, thanks for sharing

[nicanor76]

looking good, can't wait to see the next model when ready

[Reify 3D]

Here's a 26mm Yoda from our new Mini Solus. It's all in the details

[chekming1225]

This is very good base on this picture.

[Joseph Osborn]

That Yoda looks very nice. What kind of DLP projector are you using to achieve these fine results? Are you modifying the focus mechanism to get down to 25µm in the X-Y plane? How large of a printing envelope or box do you have at that resolution?