Merit 3D

DO YOUR OWN

This is for companies to do their own testing, then come to us for feedback and mass production!

Why Should You?

Purpose/Goal

Welcome to our “Do Your Own” path, designed specifically for those who wish to prototype and test their own part. We aim to equip you the the resources to successfully prototype and test on your own. This process will prepare you for mass production through us!

Some Customers Start With FDM Printers

In some cases, working with a FDM printer is the first step. Many companies have already bought smaller FDM printers to use as a way to show an idea as a physical example. 

STEP 1

Resin Basic 3K$-10K$ Option

Step 1: Purchase and Set Up the Phrozen Sonic Mega 8K or Photocentric LC Opus Printer

This step recommends printers we believe are great for the prototyping and testing stage until we mass produce for you! These printers offer great quality, speed, and material options.

Guide: Follow the setup guide related to which printer that’s bought. This includes unboxing, connecting power and other peripherals, and performing initial tests to ensure the printer is functioning correctly. Phrozen has a “Help Center” with all needed resources to setting up their printer and beginning to print. Whereas Photocentric has a “Resource Hub” for information about using their printer.

Sonic Mega 8K S Specs
System: Phrozen OS
Operation: 3.5″ Touch Panel
Slicer Software: CHITUBOX V1.9.6 and above (or others)
Connectivity: USB
Design: Technology Resin 3D Printer – LCD Type
Light Source: 405nm ParaLED® Matrix 3.0
Release Film: ACF Film
XY Resolution: 43 µm
Layer Thickness: 0.01-0.30 mm
Average Printing Speed: 600 layers/hr
Power Requirement: AC100-240V;50-60Hz
System Power: Max 240 W
Printer Size: L47.2 x W38 x H56.6 cm
Print Volume: L33 x W18.5 x H30 cm
Printer Weight: 26 kg

(Spec Information Found Here)

Photocentric Liquid Crystal Opus
System: Photocentric Studios
Operation: 7″ Touch Panel
Slicer Software: Photocentric Studios
Connectivity: USB, WiFi, Ethernet
Design: Technology Resin 3D Printer – LCD Type
Light Source: 405nm 
Release Film: High Tempered Glass
XY Resolution: 81 µm
Layer Thickness: 0.025-0.10 mm
Average Printing Speed: 18mm/hr
Power Requirement: 110-230VAC;50-60Hz
System Power: Max 500 W
Printer Size: L475mm x W415mm x 605mm
Print Volume: L310mm x W174 x H220 cm
Printer Weight: 38 kg

Sonic Mini 8K S Specs
System: Phrozen OS
Operation: 3.5″ Touch Panel
Slicer Software: CHITUBOX V1.9.6 and above (or others)
Connectivity: USB
Design: Technology Resin 3D Printer – LCD Type
Light Source: Linear Projection LED Module
Release Film: FEP Film
XY Resolution: 22 µm
Layer Thickness: 0.01-0.30 mm
Average Printing Speed: 600 layers/hr
Power Requirement: AC100-240V;50-60Hz
System Power: Max 240 W
Printer Size: L47.2 x W38 x H56.6 cm
Print Volume: L33 x W18.5 x H30 cm
Printer Weight: 26 kg

(Spec Information Found Here)

After any SLA 3D print, the parts will need some post processing done before the parts can be considered complete. The post processing consists of removing any supports, washing the excess resin of the part/s, and curing the now clean part.

Link to Phrozen Wash Mega S

Link to Phrozen Cure Mega S

Resin Pro Package -Under 30K$

Purchase Photocentric’s Liquid Crystal Magna. After purchasing, follow the resource hub to get started.

Photocentric Liquid Crystal Magna

System: Photocentric Studios
Operations: 7″ Touch Panel

Slicer Software: Photocentric Studios

Connectivity: USB, WiFi, Ethernet

Design: Technology Resin 3D Printer- LCD Type

Light Source: 460nm

Release Film: Blow Peel and Vat Lift Technology

XY Resolution: 137 µm

Layer Thickness: .025-0.35 mm

Average Printing Speed: 86mm/hr

Power Requirement: 100 VAC – 240 VAC; 50-60Hz

System Power: 500w

Printer Size: L641mm x W852mm x H900mm

Print Volume: 510 x 280 x 350mm

Printer Weight: 110Kg

The Photocentric Wash and Cure station is our recommended tools to post process prints. Some form of wash and cure is needed to achieve a good quality part. 

Washing the parts removes all the excess resin from the prints.

Curing the parts finishes the post processing and creates the end use parts. 

 

STEP 2

Material Selection and Design Preparation

Choose an appropriate resin for your project. There are a variety of resin manufacturers we partner with for mass manufacturing.

Photocentric: Offers a variety of durable resins tailored for production-grade parts. However they’re not limited to production parts, as they have prototyping and test resins on hand.

BASF: Renowned for its high-performance materials across industrial applications. A global leader of high grade bio-compatible resins.

Loctite: Specializes in high performance engineering-grade resins, providing precision and reliability for diverse manufacturing needs.

Link to all Photocentric Resins

Our Recommended and Most Commonly Used Resins

DL110HB: An incredibly versatile resin that can handle impact, compression, bending and stress fatigue without breaking or deforming.

DL110HTR Smokey Quartz Translucent: Has nearly identical properties as the DL110HB and DL110HW. DL110HTR has the fastest print time capabilities and a unique Amber appearance.

Durable: Creates functional parts that are durable and long-lasting, with high impact strength.

Duramax: Creates functional parts that are very durable and long-lasting, with high impact strength.

DL110HW: DL110HW has essentially identical properties as the black, though requires more finesse.

Flexible DL220B: A newer resin with the key properties of high elongation, impact absorption, efficient energy damping, strong tear strength, and very low water absorption.

Ultracur3D EPD 4006: Ideally suited for making large-scale objects where a hard finish is essential.

Link to all BASF Resins

Our Recommended and Most Commonly Used Resins

BASF EL4000: Ultracur3D® EL 4000 by Forward AM is the latest addition to our flexible and elastomeric resins.

BASF EL60: Ultracur3D® EL 60 by Forward AM is a very versatile reactive urethane photopolymer for highly elastic applications, combining very good torsional strength and elongation at break with high softness (Shore 75 A) and low water uptake.

BASF ST45: Ultracur3D® ST 45 B by Forward AM are reactive urethane photopolymers for Tough applications that delivers an excellent combination of high strength, plus long-term toughness and impact resistance.

BASF ST80: Ultracur3D® ST 80 W by Forward AM are reactive urethane photopolymers for tough applications.

BASF EPD4006: Ultracur3D® EPD 4006 by Forward AM is an extremely tough and durable material ideal for functional applications.

Link to all Loctite Resins

Our Recommended and Most Commonly Used Resins

Loctite IND475: Tough resin designed for tooling and molding applications, due to its high temperature resistance withstanding up to 230°C and high stiffness.

Loctite 3172: Resin that allows to produce functional parts that require high stiffness with a good surface finish and high impact resistance. Attributes are similar to Polypropylene (PP). This material is resistant to impact stress and is ideal for tooling applications, manufacturing aids, housings and consumer applications such as insoles.

Loctite IND406: LOCTITE IND406 is a tough rigid and durable 3D printing resin that performs well in industrial applications requiring high temperature use. The material offers all-round strength, good impact resistance, and high elongation. IND406 is a great alternative for traditional injection molded plastics such as ABS and PP. Stiffness, toughness, and thermal durability of this material makes it ideal for a wide variety of tools in the production floor and for final parts production.

 

You can purchase most any resin we use off of MatterHackers’ website. 

Link to MatterHackers

STEP 3

Learn the Basics of Resin 3D Printing

Resin SLA (Stereolithography) 3D printing is a type of additive manufacturing technology that uses a liquid photopolymer resin as the printing material. It works by using a UV laser to selectively cure layers of resin, solidifying them into the desired shape. This process produces highly detailed and precise objects with smooth surface finishes, making it ideal for producing intricate prototypes, jewelry, and other high-resolution parts.

1: Choose the Right Resin: Select resin appropriate for your project, considering factors like color, material properties (e.g., flexibility, durability), and compatibility with your printer.

2:Level the Build Plate: Ensure the build plate is properly leveled to the resin tank to guarantee uniform layer thickness and adhesion.

3: Calibrate Settings: Adjust printer settings such as exposure time, layer height, and lifting speed according to the resin and desired print quality.

4: Use Supports: Utilize support structures in your 3D models to prevent print failures due to overhangs and ensure successful printing of intricate designs.

5: Handle Resin Safely: Wear gloves and eye protection when handling resin, and work in a well-ventilated area to minimize exposure to fumes.

6: Resin Management: Keep resin containers sealed when not in use to prevent contamination and store them away from direct sunlight to avoid premature curing.

7: Post-Processing: After printing, rinse printed objects in isopropyl alcohol (IPA) to remove excess resin, then cure them under UV light to fully solidify the resin.

8: Fine-Tune Supports: Experiment with different support structures and orientations to minimize post-processing and achieve better surface quality.

9: Monitor Prints: Regularly check prints during the process to ensure proper adhesion and address any issues such as layer shifting or failed prints promptly.

10: Learn from Failures: Embrace failures as learning opportunities and analyze the causes to improve your printing skills and optimize future prints.

Resources: 

Links to Setting Up The Printers:

Phrozen Sonic mega 8K S

Phrozen Sonic mini 8K S

Photocentric Liquid Crystal Magna

Photocentric Liquid Crystal Opus

Links to Calibrating/Using The Printers:

Phrozen Sonic Mega 8K S Calibration; Phrozen Sonic Mega 8K S LCD Test

Phrozen Sonic Mini 8K S Calibration; Phrozen Sonic Mini 8K S LCD Test

Photocentric Liquid Crystal Magna

Photocentric Liquid Crystal Opus

Links to Post Processing Methods:

Link to Photocentric’s Wash and Cure Station

Link to Phrozen’s Wash and Cure Kit

STEP 4

Print Your Part

Print your part in your desired material. After you preform any design iterations and come to a finished product, send us your file and we’ll mass produce your part for you!

Simply send the finalized file for mass production through our contact form or instant estimate tool. This streamlined process ensures that designs meet specifications before scaling up for production.

Call 833-341-2335

Contact Form

Instant Estimate Tool

Once you’ve done your own testing and sent us an order, we’ll mass produce it for you. 

Merit3D prints and ships your parts faster than traditional methods can supply you. We send you your order, and offer feedback on your part design related to how well it can be mass produced using resin SLA printers.

Many times, we will print your part samples in many different orientations to allow the best opportunity of great quality parts. Once printed, you choose which orientation you like the best.

After you’ve checked over the orientation samples and tested the materials. We mass produce your order! This process allows you to have control over the production process like never before. 

Additive Manufacturing allows endless design changes and a wide variety of materials. Now more than ever, we are focusing on delivering manufacturing happiness through a streamlined, customer based, mass production method.

STEP 5

Mass Produce With Us, Or REPEAT!

After going through all the steps, either you have a finished part, or need to make some changes. In that case, just go back to step 4, touch up on step 3, and print your part again!

Eventually you’ll get your finished part. When that happens, we’ll mass produce it for you! Just use our instant estimate tool, or contact form to get in touch!

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