REVIEW PAPER ON PARAMETERS AFFECTING THE QUALITY OF PRINT IN DLP SYSTEM

e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020

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REVIEW PAPER ON PARAMETERS AFFECTING THE QUALITY OF PRINT IN DLP SYSTEM Pravin Jadhav-Sarnailk*1, A. R. Balwan*2, V. D. Shinde*3 *1PG

Student, Mechanical Engineering Department, DKTE Society’s Textile & Engineering Institute, Ichalkaranji, India.

*2Assistant

Professor, Mechanical Engineering Department, DKTE Society’s Textile & Engineering Institute, Ichalkaranji, India.

*3

Professor, Mechanical Engineering Department, DKTE Society’s Textile & Engineering Institute, Ichalkaranji, India.

ABSTRACT Additive manufacturing (AM) or additive layer manufacturing is the commercial manufacturing name for 3-D printing, a computer-managed technique that creates 3-dimensional objects with the aid of using depositing materials, commonly in layers. These methods are categorised usually in line with the sort of material used as liquid-based, solid-based, and powder-based additive production methods. Solid based additive production is hugely used due to its ease of use, low price, and reasonably-priced material.

Powder-based additive production is used for 3-D printing with metal substances. Metal additive production technology is the most costly among numerous additive manufacturing methods. Liquidbased additive manufacturing methods usually use photopolymer liquid resin as a raw material. It offers a completely high-quality surface finish therefore used withinside the jewelry industry and dental industry.

The price of the liquid-based additive production technique is medium regarding solid-based and powder-based additive production methods. Digital Light Processing (DLP) is a liquid-based additive production technique.

Keywords: Additive manufacturing, 3D printing, rapid prototyping, DLP 3D printing.

I.

INTRODUCTION

Additive Manufacturing refers to a technique by which digital 3-D layout information is used to build up a physical component in layers with the aid of using depositing material. The term "3-D printing" is increasingly used as a synonym for Additive Manufacturing. Term Rapid Prototyping is also used for Additive Manufacturing. Rapid prototyping is a collection of strategies used to quickly fabricate a scale version of a physical component or assembly the use of 3-dimensional computer-aided design (CAD) information. Construction of the component or assembly is generally carried out the use of 3-D printing or "additive layer manufacturing" technology. However, 3-D printing is a greater correct term, in that it describes an expert manufacturing approach which is different from traditional strategies of material removal. In Additive Manufacturing in preference to milling a workpiece from a solid block, builds up components layer by layer using materials that are available in high-quality powder form, a liquid form, or solid wire form. A variety of various metals, plastics, and composite materials can be used.

II.

LITERATURE REVIEW

Pil-Ho Lee et al. (2014) mentioned dimensional accuracy in additive manufacturing (AM) methods and concluded that the development of dimensional accuracy is one of the most important scientific challenges to enhance the characteristics of the goods by AM. This paper analyzed the research for typically used AM techniques regarding dimensional accuracy and categorized them by process characteristics, and relevant accuracy problems are examined.

Tyge et al. (2015) mentioned the characterizing of DLP 3-D Printed Primitives, Studied the resolution and reproducibility of 3-D printing methods. Centroid, rectangularity, roughness, and tilt of the top of a primitive were observed. Concluded that standard deviations for these estimates were quite small. The method was shown to have high precision when compared to a visual inspection by an expert. www.irjmets.com

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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020

Impact Factor- 5.354

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Chockalingam et al. (2016) described the optimization of stereolithography process parameters for part strength using the design of experiments.

Pointed that contribution of 3 parameters; particularly, layer thickness, post-curing time and orientation are maximum significant for the strength of the SLA 3-D printed part. Presented optimum values for parameters of SLA to achieve better strength of the product.

Olmos et al. (2017) gave an in-depth study of concepts of the DLP 3-D printer and presented the development of a prototype printer. Compared bottom-up and top-down DLP 3-D printing systems along with their benefits and disadvantages. Concluded that DLP permits printing components approximately a hundred times faster than FDM. Concluded that the good printing speed makes the DLP technique promising for more applications in general manufacturing.

Varghese et al. (2017) focused on the fabrication and characterization of ceramics using low-cost DLP 3D printing. Used customized DLP 3-D printer as a UV source to manufacture green bodies from photosensitive resins that were prepared by mixing 25-60 wtβamic with poly (ethylene glycol) diacrylate and a photoinitiator dissolved in ethanol. The 3-D-printed bodies were then sintered withinside the 12001500°C. Photogrammetry and SFM had been used to assess the accuracy of the 3-D printing technique and discovered discrepancies among the CAD model and the green body.

Lisen Ge et al. (2018) constructed up a desktop digital light processing (DLP) 3-D printer and fabricated multiple size soft pneumatic actuators integrally with speedy pace and high precision. Stated that the Bottom-up method for DLP 3-D printing has greater benefits and comfort over the Top-down technique.

Results supplied on this work proved the DLP 3-D printing method for the fabrication of pneumatic actuators offers noticeably high speed and high precision.

Kadry et al. (2019) targeted on the feasibility of using digital light processing (DLP) 3-D printers (3DP) in the fabrication of solid oral dosage forms. Concluded that the DLP system offers greater flexibility to customize numerous printing parameters also photoreactive polymer preparation and printing may be performed withinside the room. The DLP technology will permit the fabrication of capsules with distinct release properties such as immediate and extended-release tablets.

III.

METHODOLOGY

Additive manufacturing is a modern technology for fast manufacturing. There are numerous alternatives available in the market these days based on the identical principle of rapid prototyping.

Classification of Additive Manufacturing Systems: Additive manufacturing processes are classified into seven areas based on: 1.

2.

3.

Type of materials used Deposition technique The way the material is fused or solidified

The seven most important additive manufacturing methods categorized as per ASTM F42 are: 1.

2.

3.

4.

5.

6.

7.

Photopolymerization Material jetting Binder jetting Material extrusion Powder Bed Fusion Sheet Lamination Direct Energy Deposition

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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:02/Issue:09/September-2020

Impact Factor- 5.354

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Figure 1: Additive Manufacturing Processes Along with Classes of Materials and Method of Deposition.

Photopolymerization: 3-D printing technology encompasses numerous different methods that depend upon the identical primary strategy: a liquid photopolymer contained in a vat (or tank) is selectively cured by a light source.

Layer by layer, a 3-D physical item is constructed till completion. In the light polymerization (or photopolymerization) techniques, specially photopolymer is used because of the building material.

Common technology encompasses stereolithography (SLA), Polyjet, and digital light processing (DLP), and liquid crystal display (LCD) based projections. In DLP and LCD based projection approach, unlikely SLA, the projected picture hardens a layer of resin at a time till the complete 3-D model has been realized.

In the SLA technology, a single UV laser beam movements alongside the surface of photo resins in a row by row fashion that consequences in localized polymerization and solidification. Solidification is repeated in a layer by layer way till a solid 3-D item emerges. Unlike laser-based commercially available SLA printers, which do now no longer provide the power of using a very small quantity of resins for printing, DLP printers are adaptable to custom-designed resin reservoirs and small volumes of photoreactive polymers.

Digital Light Processing (DLP) system: Among the AM methods, Digital Light Processing (DLP) permits printing components approximately a hundred times quicker than classical ones as FDM (Fused Deposition Modeling).

Digital Light Processing (DLP) is an AM technology that utilizes the photopolymerization technique to manufacture 3-D objects. A DLP 3-D printer projects the picture of the component's cross-section onto the surface of the resin, while a normal video projector may be used in which the white light emitted affords sufficient UV light to resin polymerization. The exposed resin hardens at the same time as the machine's build platform (Z-axis) displaces “step by step�. DLP printing is low price and relatively precise as compared to maximum common printing techniques as FDM and SLS. Besides, a good printing speed makes this technique promising for more applications in general manufacturing.

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IV.

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TYPES OF DLP SYSTEM

There are mainly two types of DLP systems based on the direction of projection of sliced image and movement of the z-axis, bottom-up projection system, and top-bottom projection system. A bottom-up projection device has many benefits as compared to a top-bottom device. A bottom-up projection DLP system is typically preferred.

Figure 2: ‘Bottom-up’ DLP device.

V.

WORKING OF DLP SYSTEM

The 3-D geometry version of an object is first sliced into layers horizontally. The skinny layers are then transformed into 2D mask images. A light projection tool is employed to cure the photopolymer resin.

It uses a digital masking method to project a dynamically described mask picture onto the resin surface of every layer. The digital overlaying technology particularly includes 3 types: liquid crystal display (LCD), digital micro-mirror device (DMD), and liquid crystal on silicon (LCOS).

In a bottom-up projection device, the mask picture is projected onto the bottom of the resin tank and the newly cured resin adheres to the tank bottom and the cured component simultaneously. After one layer is cured, the platform is first lifted to separate the cured layer from the tank bottom and then pushed down to form an opening with the tank to cure the subsequent layer. The technique is repeated until the complete object is fabricated.

Parameters affecting the quality of print in DLP system: Unlike different UV based 3-D printers, the DLP device lends the ability to personalize numerous printing parameters such as, 1.

2.

3.

4.

5.

6.

7.

Layer thickness Curing time of each layer.

Exposure time Orientation UV intensity UV light source Wavelength

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VI.

Impact Factor- 5.354

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CONCLUSION

The Quality of 3D prints of Digital Light Processing additive manufacturing process relies upon technically on seven parameters, particularly Layer thickness, the Curing time of each layer, Exposure time, Orientation, UV intensity, UV light source, Wavelength. But among them, Layer thickness and Exposure time, the Curing time of each layer (Off time), and The orientation of the model are the crucial parameters. By controlling these critical parameters, the quality of the 3-D prints and the time required for manufacturing can be controlled as per requirement.

VII. [1]

[2]

[3]

[4] [5] [6] [7]

REFERENCES

Pil-Ho Lee, Haseung Chung (2014) “Review: Dimensional Accuracy in Additive Manufacturing Processes” Proceedings of the ASME 2014 International Manufacturing Science and Engineering Conference, MSEC2014, June 9-13, 2014, Detroit, Michigan, USA. Emil Tyge, Jens J. Pallisgaard (2015) “Characterizing Digital Light Processing (DLP) 3d Printed Primitives” Springer International Publishing Switzerland 2015 R.R. Paulsen and K.S. Pedersen (Eds.): SCIA 2015, LNCS 9127, page no. 302–313.

K. Chockalingam, N. Jawahar, K.N. Ramanathan (2016) “Optimization of Stereolithography Process Parameters for Part Strength Using Design of Experiments” Int J Adv Manuf Technol (2006) 29: Page no. 79-88.

Liliane Guardia Olmos (2017); “3d DLP Additive Manufacturing: Printer and Validation” 24th ABCM International Congress of Mechanical Engineering December 3-8, 2017, Curitiba, PR, Brazil.

Giftymol Varghese, Mónica Moral (2017) “Fabrication and Characterisation of Ceramics Via LowCost DLP 3d Printing” Boletín de la Sociedad española de cerámica y vidrio (2017).

Lisen Ge, Longteng Dong, Dong Wang (2018) “A Digital Light Processing 3d Printer for Fast And High-Precision Fabrication of Soft Pneumatic Actuators” Sensors and Actuators A. Hossam Kadry, Soham Wadnap, Changxue Xu, Fakhrul Ahsan (2019) “Digital Light Processing (DLP) 3d-Printing Technology and Photoreactive Polymers in Fabrication Of modified-release Tablets” European Journal of Pharmaceutical Sciences 135 (2019), Page no. 60-67

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