GOVERNMENT POLYTECHNIC,

NANDED
MICRO PROJECT
Academic year: 2024-25

Write a report on “Additive Manufacturing

-Digital Light Processing (DLP)”

Program: Mechanical Engineering

Program code: 0020
Course: Solid Modeling and Additive Manufacturing
Course code: 22053
Name of Guide: A.H.KADAM

1
 MAHARASHTRA STATE
BOARD OF TECHNICAL EDUCATION
Certificate
This is to certify that Sitawar Vinit Santosh ( 1655), Suryawanhi Prasad Balaji
(1656), Swami Manoj Malliakarjun (1657), Waghmare vikram Maroti (1658),
Bhavare Nagesh Pralhad(1661), of fifth Semester of Diploma in mechanical
Engineering of Institute, Government polytechnic Nanded has completed the
Micro Project satisfactorily in Subject: Power Plant Engineering for the
academic year 2024- 2025 as prescribed in the curriculum.

Place: Nanded

Date:

Subject Teacher Head of the Department Principal

A.H.Kadam R.M.Sakalkale Dr.N.L.Janrao

2
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,
MUMBAI

Micro Project Proposal

Academic Year: 2024-2025 Semester : Fifth
Program: Mechanical Engineering Scheme: ME5I
Course: SMA Course Code: 22053
Class: ME5I Date:

Title of Micro Project : Write a report on “Additive Manufacturing –

Digital Light Processing (DLP)”

Group Members:

Sr. No. Roll no Name of Students Signature

1 1655 Sitawar Vinit Santosh
2 1656 Suryawanshi Prasad Balaji
3 1657 Swami Manoj Mallikarjun
4 1658 Waghmare Vikram Maroti
5 1661 Bhavare Nagesh Pralhad

Subject Teacher Designation: Lecturer in Mechanical Department.

Comments by guide:

Name of Faculty :- A.H.Kadam

Signature :-

3
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION, MUMBAI

MICRO PROJECT
Progress Report / Weekly Report
Name of the Project: Write a report on “Additive Manufacturing –Digital Light
Processing (DLP)”

Course: SMA

Program: Mechanical Engineering

Roll No. 1655,1656,1657,1658,1661

Week Activity programed Date

1st Discussion and finalization of group

2nd Discussion and finalization of topic

3rd Preparation and submission of abstract

4th Literature review

5th Collection of data

6th Collection of data

7th Collection of data

8th Collection of data

9th Discussion and outline of content

10th Formulation of content

11th Editing and 1st proof reading of content

12th Editing and 2nd proof reading of content

13th Complication of report and presentation

14th Submission

Sign of guide

4
 ANNEXURE II

Evaluation Sheet for the Micro Project

Academic Year: 2024-25
Name of the Faculty: A.H.Kadam
Course: SMA Course code: 22053 Semester: 5th
Title of the project: Write a report on “Additive Manufacturing –Digital Light
Processing (DLP)”

• COs addressed by the micro project

CO1: Understand the basic principles of Digital Light Processing
CO2: Understand the functioning of Digital Light Procesing
• Practicle ourcome
PO1: Identify the different components of Digital Light Processing
• Outcomes in Affective domain:
ADO1: Develop teamwork and collaborative problem-soving skills in group
tasks related to energy project planning
ADO2: Exibit curiosity and proactive apporach in researching cutting edge
developments Digital Light Processig.

Roll no. Student name Marks obtained

Marks for by the individual Total
Group based on viva Marks
Work (06) (04) (10)
1655 Sitawar Vinit Santosh

1656 Suryawanshi Prasad Balaji

1657 Swai Manoj Mallikarjun

1658 Waghmare Vikram Maroti
1661 Bhavare Nagesh Pralhad

Name of Faculty :- A.H.Kadam

Signature :-

5
 Introduction
Digital Light Processing (DLP) is a technology primarily used
in projectors and video displays, developed by Texas
Instruments. It employs a digital micromirror device (DMD)
to create images by reflecting light.

What Is DLP 3D Printing?

DLP is a vat polymerization process in which a conventional light
source cures a photopolymer resin vat. This process utilizes a digital
micromirror device (DMD) with countless tiny mirrors that pivot to
direct UV light precisely onto the resin. DLP printers excel at creating
highly detailed parts with exceptional accuracy and a smooth surface
finish, surpassing many other 3D printing technologies.

6
How Does DLP 3D Printing Work?
DLP printing begins by creating a digital model and then slicing it
into thin horizontal layers. Each layer represents a cross-sectional area
of the model. The DLP projector displays these layers on the liquid
resin’s surface. Exposing the resin to light causes the liquid polymer
to harden and form a solid layer. The build platform moves, allowing
fresh resin to cover the previous layer, and this process repeats.

Before we delve into the various stages of the DLP printing process,
there are five key printing terms and components to understand.

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What is a Voxel?
A voxel, also known as a volumetric pixel, is the smallest unit of a 3D
print, similar to how a pixel is the smallest unit of a digital image. In
DLP 3D printing, each voxel corresponds to a specific point in the
printed object, with its position defined in three-dimensional space.

This concept is crucial as it creates objects with intricate internal

structures and detailed exteriors. Manipulating individual voxels
using the DLP printer’s light source enables high resolution and
precision, setting DLP printing apart from other additive
manufacturing techniques.

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Digital Light Projector Screen
The digital light projector is the main component responsible for the
DLP 3D printing process. It uses a digital micromirror device (DMD)
with thousands of tiny mirrors to project an image onto the resin
surface. By directing UV light onto the resin, specific areas are
hardened layer by layer to create the final object.

Vat
The vat, or resin tank, stores the liquid photopolymer resin during
printing. It has a transparent bottom to allow the light from the digital
projector to pass through and cure the resin. The vat’s design is
crucial for DLP printer operation, exposing a thin and even resin layer
to light for each print. Proper maintenance or replacement of the vat’s
bottom is necessary to maintain consistent print quality.

Build Platform
The build platform, or build plate, is the surface where the resin cures
and the printed object forms. It starts close to the vat’s bottom,
allowing printing of the first layer. After each layer cures, the build
platform moves up incrementally to accommodate the next layer.
Precise control of the build platform’s movement ensures it achieves
the desired layer height.

Elevator
The elevator mechanism controls the vertical movement of the build
platform on the z-axis. This precise adjustment allows each layer to
be accurately positioned and exposed to UV light for curing. It
ensures the creation of detailed and dimensionally accurate parts layer
by layer.

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What are the stages of a typical DLP 3D
printing project?
1. Design Creation and Preparation: 3D modeling software
creates a digital model and slices it into thin, horizontal layers for
printing. The slicing software converts the model into a series of
images. Each represents a layer of the object.
2. Resin Tank Preparation: To begin the printing process, the
resin tank, which holds the liquid photopolymer resin, is prepared.
This tank contains the material that will form the final printed
object.
3. Build Platform Calibration: Calibration of the build platform,
or build plate, is vital to ensure proper adhesion of the first layer and
precise alignment of subsequent layers.
4. Layer-by-Layer Printing: The DLP projector displays an
image of the first layer on the liquid resin’s surface. The UV light
exposure solidifies the resin where it strikes, forming the first layer
of the printed object.
5. Build Plate Movement: After each layer cures, the build plate
moves, typically in the z-axis direction, to allow the flow of a new
resin layer over the previously solidified layer. The distance moved
corresponds to the layer height, usually between 25 and 100
microns.
6. Repeating the Exposure Process: Steps 5 and 6 are repeated,
with the DLP projector displaying each subsequent layer and the
build plate moving accordingly until the printing of the entire object
finishes.
7. Washing: After removal from the build plate, the object is
subjected to a washing process. This crucial step involves
immersing the object in a solvent or using a specialized washing
machine to remove any uncured resin. Effective washing ensures
that the surface is clean and prepared for the next stage of post-
processing.
8. Curing: Following the washing, the object undergoes curing under
UV light. This process solidifies the resin, enhancing the

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 mechanical properties and stability of the final product. Curing is
essential for achieving the desired durability and structural integrity
of the 3D printed object.
9. Support Removal and Finishing: Removing any supports
used during printing the object happens once the exposed liquid
polymer hardens. The object may then undergo sanding or finishing
to enhance its surface quality.
10. Quality Inspection and Testing: The final step involves
inspecting the printed object for any defects and conducting
mechanical tests, if necessary, to ensure it meets the required
specifications.
What Are the Technical Characteristics and
Specifications of DLP 3D Printing?
DLP 3D printers offer unique characteristics and outperform other 3D
printing methods. Fast printing speed, precise layer height,
exceptional surface finish, high resolution, and versatile support
material make them an ideal choice for various applications.

Printing Speed
With a typical printing speed of 25 mm/hour, DLP printers can
produce parts much faster than other methods. The DLP projector’s
ability to cure an entire resin layer in a single exposure significantly
reduces printing time.

Layer Height
The UV light from the printer’s light source can cure resin to a depth
of up to 100 microns, allowing layer heights between 25 and 100
microns. This precision is crucial for creating complex parts with tight
tolerances.

DLP-printed parts boast a superior surface finish. Precise control over

resin curing gives a smoother finish than using other methods. This
quality makes DLP printing ideal for visual prototypes and parts that
require minimal post-processing.

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 Resolution
Using digital micromirror devices (DMD) within the digital light
projector means DLP printers can achieve extremely high resolutions.
They can create intricate designs, finely detailed features, and smooth
surfaces, which makes them perfect for detailed visual prototypes.

Support Material
Support structures uphold overhanging designs, maintain dimensional
accuracy, and prevent deformation during the printing process.
Careful design and planning ensure that supports fulfill their role
without compromising the final part’s aesthetics or integrity.

Post-Processing Requirements
DLP-printed parts undergo post-processing. Typically, this involves
washing to remove uncured resin, UV curing for maximum strength,
and removing support structures. Additional processes like sanding,
polishing, or painting can enhance appearance and surface finish.

Washing
For washing DLP 3D printed parts, the goal is to remove any excess
or uncured resin from the surface and cavities of the print. The most
commonly used solutions are:

• Isopropyl Alcohol (IPA): A popular choice due to its effectiveness

in dissolving uncured resin. Parts are usually submerged in an IPA
bath and gently agitated to remove the resin. However, IPA is
flammable and requires handling and disposal in accordance with
safety regulations.
• Ethyl Alcohol (Ethanol): Similar to IPA, ethanol can also be used to
clean 3D printed parts, though its availability and cost might vary.
• Commercial Cleaning Solutions: There are also specialized cleaning
solutions designed specifically for 3D printed parts. These solutions
are formulated to be effective at resin removal while being less
harsh on the parts and potentially safer for users compared to IPA or
ethanol.

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• Water Washable Resins: Some DLP printers use resins that can be
cleaned with water, eliminating the need for chemical solvents.
These resins are designed to be easily washed away with water,
simplifying the cleaning process.
• Sunlight: Direct exposure to sunlight is a cost-effective method for
curing, as natural sunlight emits UV light. However, this method
offers less control over exposure time and intensity.
• UV Nail Lamps: For smaller parts or hobbyists, UV nail lamps used
for curing gel nail polish can be repurposed for curing 3D prints.
Strength and Accuracy
The choice of resin determines its mechanical properties, making it
suitable for many applications. Precise dimensions, perfect fit, and
conformity to original models are essential for custom medical
implants and tightly fitted components.

What are the types of materials used in DLP 3D

printing?
DLP 3D printing relies on liquid resin for creating solid structures
layer by layer. These photopolymer resins react to specific light
wavelengths, like UV, to harden. The choice of resin is crucial for
determining mechanical properties, resolution, and application of
printed parts.

Let’s explore the commonly used resins in DLP 3D printing, their

properties, and why they are well-suited for this technology:

• Standard Resin: Highly versatile, standard resin is perfect for

many applications, offering an optimal balance between strength
and detail. It’s ideal for prototypes, art objects, and functional parts
that require high accuracy.
• Tough Resin: Designed to mimic the strength and stiffness of
ABS plastic, tough resin is ideal for parts that will undergo
significant stress or strain. It is popular in functional prototyping,
snap-fit assemblies, and durable casings.

13
• Flexible Resin: This resin provides excellent flexibility and
bendability, making it suitable for applications like hinges, wearable
prototypes, and items that require rubber-like properties.
• High-Temperature Resin: With a high heat deflection
temperature, this resin is perfect for applications that require parts to
withstand elevated temperatures, such as molds, heat-resistant
fixtures, and automotive components.
• Durable Resin: Its outstanding impact resistance and smooth
glossy finish make durable resin popular for parts created to
withstand repeated stress cycles without fracturing.
• Castable Resin: A popular choice in the jewelry industry,
castable resin burns out cleanly without leaving ash or residue,
making it perfect for investment casting of intricate designs.
• Water Washable Resin: This resin simplifies the post-
processing stage as it can undergo cleaning with water instead of
alcohol. It also reduces handling time and exposure to chemicals.
• Dental Resin: Specifically formulated for dental applications,
dental resins are biocompatible and designed for producing crowns,
bridges, and orthodontic models with exceptional detail and
accuracy.
• Ceramic-Filled Resin: This resin combines the properties of
ceramics and polymers. Ceramic-filled resins are ideal for parts
requiring high-temperature resistance, stiffness, and a smooth finish.
• Clear Resin: Ideal for applications that demand transparency,
such as lenses, fluidics, and light guides, clear resin can be polished
to achieve a glass-like transparency.

What are The Advantages of DLP 3D Printing?

Digital Light Processing (DLP) 3D printing stands out in the additive
manufacturing industry for its ability to create highly detailed and
precise parts.

14
 Digital light processing brings some notable benefits over other types
of 3D printing. It’s a preferred choice for professionals across various
fields.

Below, we explore some of the main advantages that DLP 3D printing

offers:

• High Resolution and Detail: DLP printers have ultra-high

resolution thanks to digital micromirror devices (DMD). The tiny
mirrors in the DMD allow precise control over the UV light
exposure, enabling the creation of parts with intricate details and
smooth surface finishes.
• Speed: DLP printing is known for its speed. The ability to cure an
entire resin layer simultaneously, rather than tracing the layer’s
outline with a laser or extruding filament, significantly reduces the
time needed to print objects.
• Efficiency: The process is highly efficient in material use and
energy consumption. DLP printers use the precise amount of resin
needed for each layer, minimizing waste.
• Versatility in Materials: DLP technology supports a wide range
of resins, each with unique properties that cater to different
applications. DLP printers can produce parts for diverse
applications using standard resins or tough, flexible, high-
temperature, and castable options.
• Dimensional Accuracy: The precision of DLP printing results in
parts with exceptional dimensional accuracy, making it suitable for
applications where tight tolerances are critical, such as in the dental
and jewelry industries.
Does Digital Light Processing Printing Have
Any Disadvantages?
While Digital Light Processing (DLP) 3D printing offers numerous
advantages, including high speed, precision, and efficient use of
materials, DLP technology has limitations.

15
 Understanding the potential drawbacks of DLP 3D printing can help
you make informed decisions about the best printing methods for your
specific needs.

Here are some of the disadvantages of digital light processing when

compared to other 3D printing processes:

• Limited Material Options: Although DLP technology supports

a wide range of resins, it’s generally more restricted compared to
technologies like Fused Filament Fabrication (FFF), which can use
a variety of thermoplastics and composites.
• Size Constraints: The build volume of DLP printers, especially
desktop models, can be smaller than that of some 3D printers,
limiting the maximum size of the objects they can create.
• Dependency on Resin Properties: The mechanical properties
and durability of printed parts produced by DLP are highly
dependent on the resin used. Some resins may not match the
strength or thermal stability of materials used in other 3D printing
methods.
• Cost of Materials: High-quality DLP resins can be more
expensive than the materials used in other forms of 3D printing. The
added expense potentially increases the cost per part, especially for
large-volume production.
• Sensitivity to Light and Oxygen: Photopolymer resins used in
DLP printing can be sensitive to ambient light and oxygen.
Incorrectly storing and handling materials can affect the longevity
of printed parts.
• Messy: Post-processing of DLP prints like washing the printed
parts in solvents like isopropyl alcohol to remove any uncured resin
can be messy. Additionally, spills of resin or solvents need to be
cleaned up immediately to prevent damage or staining. here are
some extra points:
• Spills and Splashes: Liquid resins can easily spill or splash
during handling, leading to a messy workspace. Cleaning up resin
spills requires immediate attention, as uncured resin can be sticky
and difficult to remove once it hardens.

16
• Resin Containers: Pouring resin into the printer’s vat, or
returning unused resin to its container, can be tricky without spilling
so you will have to be extra careful.
What are the Applications of DLP Printers in
Various Industries?
Many industries use Digital Light Processing 3D printing.

Here’s how DLP 3D printing is making an impact across various

sectors:

• Jewelry Making: DLP printing is widely used in the jewelry

industry to create intricate patterns for molding. Its exceptional
quality and resolution make DLP printing ideal for producing
complex jewelry pieces. Designing jewelry with CAD software and
printing it with a DLP printer can create plaster or silicone molds.
Mold-making resins can fully decompose in a furnace, leaving no
residue. These molds are filled with molten metal, resulting in
jewelry showcasing intricate designs while minimizing the use of
raw materials.
• Dental Industry: DLP printers play a crucial role in the dental
field by producing highly accurate dental models, crowns, bridges,
and clear aligners for orthodontic treatments. The precision of DLP
technology ensures a perfect fit for patients, enhancing the
effectiveness and comfort of dental appliances.
• Medical Sector: DLP technology is instrumental in
manufacturing customized prosthetics and implants tailored to each
patient’s anatomy. Additionally, it is used for creating detailed
anatomical models for surgical planning, training, and patient
education, leading to improved medical procedures and outcomes.
• Prototype Development: DLP printers are invaluable in
engineering and design for rapid prototyping of product designs.
The ability to rapidly transform concepts into high-fidelity
prototypes accelerates the development process, enabling faster
iterations and improvements.

17
• Education and Research: DLP printing is a powerful tool in
academic settings, empowering students and researchers to bring
their theoretical designs to life for experimental and educational
purposes. Hands-on experience drives innovation and learning,
particularly in STEM fields.
• Entertainment and Art: DLP printing fuels creativity in art and
entertainment, allowing artists and designers to transform their
visions into reality. Create detailed figurines and props for movies
or craft bespoke pieces for art installations. DLP printing’s attention
to detail supports pushing the boundaries of creativity.
How Much Does DLP Printing Cost?
Like any technology, digital light processing comes with costs, which
can vary widely depending on several factors, including the printer
model, the type of resin used, the scale of production, and operational
expenses such as maintenance and post-processing supplies. Here’s a
closer look:

Here are some of the most popular resins and their average costs:

• Standard Resin: Typically costs between $50 to $100 per liter.

Suitable for general prototyping.
• Tough Resin: Priced around $80 to $150 per liter. Perfect for
parts requiring higher strength.
• Flexible Resin: Ranges from $100 to $200 per liter. Ideal for
objects needing flexibility.
• Dental and Castable Resins: These specialized resins cost
between $100 to $300 per liter, reflecting their use in precise dental
work and jewelry making.
How much does a DLP 3D Printer Cost?
For those interested in purchasing a DLP 3D printer, the market offers
a wide selection ranging from entry-level to high-end models.
Desktop printers, ideal for hobbyists and small businesses, can be
found in the $1,000 to $5,000 range. However, professional-grade and
industrial DLP printers, which offer larger build volumes and higher
precision, can cost anywhere from $5,000 to over $10,000.

18
 Raise3D DLP Printer
A notable example of a high-performance DLP 3D printer is the
Raise3D DF2. The DF2, designed for small-batch production, delivers
high precision, repeatability, and reliability. At a starting price of
$4,999.00, the Raise3D DF2 is optimal for engineering prototyping,
manufacturing aids, and low-volume production. It supports a diverse
selection of high-performance engineering resins, making it versatile
for various applications. The investment in a machine like the
Raise3D DF2 underscores the commitment to quality and efficiency
in 3D printing. It gives users a tool capable of meeting the demands of
professional-grade projects.

What are Key Factors to Consider When

Selecting a DLP Printer?
When embarking on the journey of selecting a DLP printer, there are
several pivotal factors you should take into account.

These considerations will guide you in making an informed decision,

ensuring that the DLP printer you choose aligns with your
requirements and objectives.

• Resolution and Precision: The resolution of a DLP printer is

paramount, especially for applications requiring fine details, such as
jewelry and dental models. Higher-resolution printers can produce
parts with intricate details and smooth surfaces. For example, the
Raise3D E2 is renowned for its exceptional resolution, making it a
favored choice among professionals requiring high-detail prints.
• Build Volume: The build volume determines the maximum size
of the objects you can print. If your projects typically involve large
parts or you prefer to print multiple small items in one go, a printer
with a larger build volume.
• Material Compatibility: DLP printers use photopolymer resins
that vary in properties and applications. Some printers are
compatible with various materials, offering versatility for different
projects. For example, the Raise3d E2 is compatible with multiple

19
 resins, allowing users to print objects ranging from flexible to high-
strength parts.
• Print Speed: DLP printers are generally faster than SLA printers
because they cure an entire resin layer at once. Print speed can
significantly impact productivity, especially in a commercial
setting. Raise3D printers are known for their rapid print speeds
without compromising output quality.
• Post-Processing Requirements: DLP-printed parts often
require cleaning and curing. Consider the ease of post-processing
and whether the printer manufacturer provides compatible cleaning
and curing solutions.
• Cost and Budget Considerations: The initial cost of the
printer and the ongoing expenses for resins and replacement parts
should fit within your budget. While some printers, like the Raise3D
DF2, might have a higher upfront cost, they offer precision and
reliability that can prove cost-effective in the long run for small-
batch production and prototyping.

Consider the case of a small jewelry design studio that opted for the
Raise3D DF2. The studio required a printer capable of producing
intricate designs with precision and reliability. Despite the higher
initial investment, the DF2 was compatible with high-performance
engineering resins, and its optimized features for prototyping
provided the studio with the ability to create detailed molds for their
unique jewelry pieces efficiently.

This decision not only enhanced the studio’s design capabilities but
also streamlined its manufacturing process and saved costs in the long
term, demonstrating the importance of selecting a DLP printer that
aligns with specific needs and industry requirements.

20
 What are the Differences between DLP and
SLA 3D Printers?
DLP and SLA utilize UV light to cure photosensitive polymers, but
how they achieve this is fundamentally different.

As already discussed, DLP uses a digital micromirror device (DMD)

composed of hundreds of thousands of tiny mirrors, each capable of
pivoting to direct UV light onto the surface of the resin.

To provide a better understanding, let’s compare DLP and SLA across

several critical factors:

• Resolution and Precision: SLA printers generally have a higher

resolution and precision than DLP because the laser can draw fine
details more accurately.
• Speed of Printing: DLP printers are often faster than SLA
printers because the digital light projector screen can cure an entire
layer of resin in one go, whereas SLA printers have to trace the
pattern of each layer with a laser point.
• Suitability for Large Prints: DLP technology, with its array of
mirrors on the DMD, can be less effective for larger prints, as the
light can lose uniformity across a wide area. In contrast, SLA can
maintain high detail for large objects, though it might be slower.
• Durability of Prints: Since SLA can achieve higher precision,
the prints are finely detailed and structurally strong. DLP prints are
still quite durable but might lack intricacies on minute features.
• Ease of Use: DLP printers typically come calibrated and ready to
print, making them more user-friendly for beginners. SLA printers
might require more fine-tuning and calibration efforts.
• Cost of Equipment: Entry-level DLP printers are more
affordable than SLA printers. Price can be a determining factor for
hobbyists or small businesses choosing between the two
technologies.

21
• Maintenance: DLP printers have fewer moving parts, which can
lead to lower maintenance costs and effort over time, whereas the
laser and complex mechanics of SLA printers might need more
regular servicing.

22
 Conclusion
DLP 3D printing is an incredible tool that changes how
we turn ideas into real-life objects. It’s super versatile
and handles all sorts of materials; whether durable parts
for machines or fine details for jewelry, it handles it. If
you work in medicine, jewelry, or car manufacturing,
learn how DLP 3D printers can make items more
precise, faster, and better quality. And DLP 3D printer
technology keeps getting better and better. Just imagine
how DLP 3D printers could help you with your
projects.

24
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