Fraunhofer ILT and Rapid Shape GmbH are developing “TwoCure”, a resin-based 3D printing process that eliminates the need for supports.

When it comes to printing objects with high resolution and impeccable accuracy, SLA technology offers some immense benefits over FDM 3D printing. However, one downfall of both processes is the frequent need for pesky support structures.

Using many of the same principles from SLA and DLP technology, the Fraunhofer Institute for Laser Technology ILT and Rapid Shape GmbH are working on a new 3D printing method that would do away with supports.

According to the research team, this “TwoCure” process provides more efficiency and productivity compared to traditional SLA 3D printing.

The technique still uses a liquid resin that is assembled in the printer layer-by-layer, and uses an LED light unit similar to the kind that Rapid Shape GmbH produces.

“Much like with a projector, an image is projected into the resin bath and the polymer hardens in the areas that are illuminated. The resin in other areas initially remains liquid,” says Holger Leonards and Andreas Hoffmann, project managers at Fraunhofer ILT.

TwoCure Enables the Creation of “Free-Floating” Components

What makes the process unique is that it solidifies the liquid monomer both photochemically with light and thermally through cooling. This enables the support material to liquify and drain away in an instance. What remains is a 3D printed component that only needs to undergo post-curing and post-processing.

Another major benefit of this process is the ability to create “free-floating” components. Not only does that mean that supports are no needed, but also that the object doesn’t even need to be attached to a print platform.

“Furthermore, we can create 3D components directly in the build volume, anywhere we choose. The components no longer have to be built on platform. Because the total build volume is being used more efficiently, each 3D printing job can create significantly more parts,” explains Holger Leonards.

The development of TwoCure could be especially useful for jewelry designers. Professionals in this field would be able to manufacture objects without the laborious process of removing support structures from the model. The research team has already successfully tested the new polymer 3D printing process on jewelry models.

The material and photochemical process were developed by Fraunhofer ILT. Meanwhile, Rapid Shape created the procedure and systems technology. The first prototype of this printer is currently being developed, and should see series production sometime in the near future.

The project is a part of the Central Innovation Program for SMEs (ZIM), which is funded by the German Federal Ministry for Economic Affairs. Fraunhofer ILT experts will be presenting the technology at the upcoming formnext 2017 show, which takes place from November 14 to 17 in Frankfurt.

Source: Fraunhofer