Classic debates keep life spicy. Horizontal or vertical mill? iPhone or Android? Deep dish or thin crust? In the world of polymer 3D printing, one point of contention is the trade-offs between digital light processing (DLP) and stereolithography (SLA). DLP uses a light source to cure a liquid photopolymer and offers higher throughput but limited resolution, whereas SLA uses a UV laser to solidify liquid resin with greater accuracy but lower output. IMTS exhibitor Axtra3D solves this classic debate with its advanced Hybrid PhotoSynthesis (HPS) technology that combines the best attributes of DLP and SLA in one system: the Lumia X1 3D printer. Founded in Charlotte, North Carolina, in 2021, Axtra3D developed a patented light engine where a light projector cures the majority of the layer for speed and, simultaneously, a laser precisely cures the contours of the layer. The marriage of these two technologies into HPS benefits the industry because the Lumia X1 compensates for the weaknesses of both. Another company innovation further enhances speed and quality by eliminating the hydrostatic forces associated with traditional DLP and LCD printers. Axtra3D highlighted several examples, including a bracket: SLA can print four brackets in 2,070 minutes with high resolution. DLP can print four of the same part in 254 minutes, but the curved surface finish has visible “stair-stepping” between different layer heights. HPS can also print four brackets in 254 minutes, but with the hybrid approach, the Lumia X1 can achieve feature resolutions of 50 micros and SLA-grade surface resolution of 20 microns. It enables a solution with no tradeoffs between precision and print throughput.  “The capabilities of our Lumia X1 3D printer were very well received by the leaders of organizations visiting IMTS. We successfully sold one printer directly on the show floor, with a second sale following a week later,” says Rajeev Kulkarni, chief strategy officer at Axtra3D. “We can’t discuss the customer who purchased at the show because they were government affiliated, but we can say that they were looking to achieve bigger part volume (up to 249 x 140 x 495 mm), greater accuracy, and speeds up to 20 times that of conventional DLP and SLA systems.” Kulkarni notes that other customers are successfully using the Lumia X1 for concept injection molding utilizing ceramic mold inserts made from Ultracur3D RG 3280, a ceramic-loaded polymer. The ceramic mold inserts can deliver 300 to 3,000 shots using materials like PC, PP, ABS, TPE, and TPU. Additionally, the printer is being used to manufacture end-use electronic connectors, support low-volume production, provide dental solutions, and print silicone tubing, gaskets, bellows, and seals. “HPS technology is ideal for service bureaus working with industrial and medical customers due to its rapid material changeover and extensive materials ecosystem,” says Kulkarni. “Innovation runs deep within the visitors at IMTS, so for a new technology such as ours, it’s a show that brought benefits beyond measure. The show exceeded our expectations, with more than 50% of our leads coming from new, high-value prospects, from a variety of industries. We plan to exhibit at the show again next time.” To learn more about Axtra3D’s solutions, including the ability to experiment with a wide range of materials, visit axtra3D.com or watch a video featuring Kulkarni at Formnext 2024. To explore more companies exhibiting in the Additive Manufacturing Sector, accelerated by Formnext, review the list of companies on imts.com.

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Additive Manufacturing / 3D Printing

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