ADDITIVE MANUFACTURING via CARBON 3D
Cutting the edge,
and your timelines
In Additive Manufacturing, your only limit is your own imagination
Carbon 3D Printing for High-Performance, Complex Geometries
At Aprios, we leverage the power of Carbon 3D printing technology to deliver high-performance parts with intricate geometries quickly and efficiently. Our advanced capabilities ensure increased strength and durability, enabling the creation of complex designs that traditional methods cannot achieve. With our extensive expertise, we catch what others might miss, avoiding common pitfalls and ensuring superior results.
Start Your Instant Quote
- Upload your Design (accepted file formats include.stl, .obj, .wrl, .stp, .iges, .3mf, .dxf, .dwg, and .zip)
a. Your confidentiality is guaranteed with world-class security protocols. - Receive Feedback on Pricing and Printability (this may take up to 30 seconds
- Submit Order Draft to Aprios for Review
- Once Aprios approves the order, submit a Purchase Order using the secure portal or pay by credit card
- Updates on order progress and shipping providing via email automatically
- For help with design, follow Carbon DLS guidelines document found here
Design for Additive Manufacturing
In Additive Manufacturing, Design for Manufacturing (DFM) plays a crucial role in optimizing the production process. By integrating DFM principles, we ensure that your designs are tailored for additive technologies, maximizing efficiency and performance. This involves leveraging the unique capabilities of 3D printing, such as creating complex geometries and lattice structures, which are not feasible with traditional manufacturing methods. Our expertise in DFM helps you reduce material usage, minimize waste, and achieve faster production cycles, ultimately leading to cost-effective and high-quality parts.
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Optimize Part Orientation
Minimize Supports: Orient parts to minimize the need for support structures, which can reduce material usage and post-processing time. For example, orienting a complex part like a lattice structure horizontally may require fewer supports compared to a vertical orientation.
Enhance Surface Quality: Position the part to optimize the surface finish on critical areas. For instance, orienting the functional surface of a prosthetic limb component upward can ensure a smoother finish without support marks.
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Design for Minimal Post-Processing
Integrated Features: Design features like threads or snap-fits directly into the part to avoid additional machining or assembly. For example, embedding threaded inserts into a custom connector part reduces the need for manual thread cutting.
Reduce Supports in Critical Areas: Place supports in non-visible or non-functional areas to minimize post-processing impact. For instance, designing a shoe midsole with support structures on the internal surfaces avoids affecting the external aesthetics.
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Lattice Structures
Lattice and Honeycomb Structures: Use lightweight lattice or honeycomb structures to reduce material usage and print time while maintaining strength. For example, designing a drone frame with internal lattice structures can significantly reduce weight without compromising rigidity.
Variable Density: Employ variable density infills to optimize the balance between weight and strength. For instance, a helmet liner can have denser structures in high-impact areas and lighter structures elsewhere.
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Functional Integration
Combine Multiple Parts: Integrate multiple components into a single printed part to reduce assembly time and improve structural integrity. For example, a complex assembly like a multi-functional tool can be printed as a single piece with moving parts.
Embedded Channels: Design internal channels for cooling, wiring, or fluid flow directly into the part. For example, printing a manifold with internal fluid channels can eliminate the need for post-processing drilling.
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Material Optimization
Select Appropriate Resins: Choose resins that meet the mechanical and thermal properties required for the application. For instance, using a high-strength resin for load-bearing parts like a bicycle frame ensures durability and performance.
Tailor Material Properties: Use Carbon's proprietary resins with specific characteristics such as elasticity for flexible components like gaskets or high impact resistance for protective gear.
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Surface Finish and Accuracy
Design for Surface Quality: Plan for the best possible surface finish by avoiding overhangs and steep angles where supports are necessary. For example, designing an eyewear frame with gentle curves reduces the need for support structures, leading to a smoother finish.
Dimensional Accuracy: Account for the dimensional accuracy and tolerance levels of Carbon DLS technology. For instance, designing an interlocking mechanism with appropriate clearances ensures a proper fit without post-processing adjustments.
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Simulation and Iteration
Use Design Engine Tools: Leverage Carbon's Design Engine to simulate and optimize the part design, ensuring manufacturability and performance. For example, running simulations on a complex mechanical part can identify potential stress points and optimize the design for durability.
Iterative Prototyping: Utilize the rapid prototyping capabilities of Carbon DLS to iterate and refine designs quickly. For instance, producing multiple iterations of a medical device component allows for thorough testing and refinement before final production.
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Efficient Packing and Printing
Optimize Build Volume: Arrange parts within the build volume efficiently to maximize the number of parts printed per run. For example, nesting smaller components around larger parts can fully utilize the printer's capacity.
Batch Production: Design parts that can be efficiently produced in batches, reducing overall production time. For example, designing a series of small clips or fasteners that can be printed simultaneously in a single build.
![Supply chain IMGs (3)](https://www.aprios.com/hs-fs/hubfs/Supply%20chain%20IMGs%20(3).png?width=1080&height=1080&name=Supply%20chain%20IMGs%20(3).png)
Aprios Capabilities
Our additive manufacturing meets your project’s specific needs through the utilization of a variety of advanced manufacturing technologies, inducing medical device prototyping.
- Advanced Additive Manufacturing Technology: Precision and efficiency through state-of-the-art 3D printing and additive manufacturing.
- Rapid Prototyping: Rapid tool validation with industry-leading turnaround times.
- Production-Grade Parts: End use parts designed for durability and quality.
- Material Versatility: The right materials for your projects, including high-temperature and engineered resins.
Any Industry - Every Industry
For decades, Aprios has delivered for clients in every conceivable industry.
Medical, aerospace, automotive, electronics, medtech, and much more, we work for every company that needs quality delivered in a timely manner.
Fast and efficient medical prototyping: Our team produced a prototype for a medical client in less than 24 hours, advancing their development process by two years from their original estimates. They could go to clinical trials over 48 months sooner than originally projected.
- Medical: Precision, reliability in medical device prototyping and production in a clean room as needed.
- Aerospace: Exceeding industry standards with high-performance parts to exacting specifications.
- Automotive: Durable and cost-effective, we deliver the parts your automotive design requires.
- Electronics: Complex geometries and fine detail work are how we deliver for the electronics industry.
![Supply chain IMGs (4)](https://www.aprios.com/hs-fs/hubfs/Supply%20chain%20IMGs%20(4).png?width=1080&height=1080&name=Supply%20chain%20IMGs%20(4).png)
Additive Manufacturing- Frequently Asked Questions
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What is Carbon DLS technology?
Carbon DLS (Digital Light Synthesis) is an advanced 3D printing technology that uses digital light and oxygen-permeable optics to produce high-resolution, durable parts quickly and accurately. This technology is ideal for producing complex geometries and end-use parts.
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What materials can be used with Carbon DLS?
Carbon DLS supports a variety of materials, including rigid and flexible polyurethanes, epoxies, and elastomers. These materials offer a range of mechanical properties to meet diverse application needs.
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How does Carbon DLS compare to traditional 3D printing methods?
Carbon DLS offers higher resolution, better surface finishes, and faster production times compared to traditional 3D printing methods. It also provides superior mechanical properties, making it suitable for end-use parts and prototypes.
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Can you produce functional prototypes with Carbon DLS?
Yes, Carbon DLS is ideal for producing functional prototypes that closely mimic the properties of injection-molded parts. This allows for thorough testing and validation before moving to full-scale production.
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What are the typical applications for Carbon DLS?
Carbon DLS is used for a wide range of applications, including automotive components, medical devices, consumer products, and industrial parts. Its versatility makes it suitable for both prototyping and end-use manufacturing.
Ready to explore the possibilities?
Our experts will guide you through the process, giving you tailored advice for every step of your project.