Month: July 2024

In resin-based 3D printing, post-processing is crucial for high-quality parts. After photopolymer resins are cured, printed objects are often covered in excess resin that must be removed before further post-processing steps. Traditionally, this is done by manually submerging the parts in isopropyl alcohol (IPA) and scrubbing them, which is both labor-intensive and risky for the overall environment.

IPA poses significant challenges in additive manufacturing due to its flammability, which increases workplace accident risks and releases volatile organic compounds (VOCs). These VOCs degrade air quality and can cause respiratory issues. Additionally, the repetitive task of scrubbing parts with IPA can lead to technician fatigue and inconsistencies in part quality.

Addressing Safety and Efficiency

To tackle these challenges, PostProcess Technologies has developed automated solutions that eliminate the need for IPA by combining innovative hardware, proprietary software, and additive-specific chemistries. They have engineered a workflow that effectively cleans excess resin while addressing safety and environmental concerns.

In this process, printed parts are placed into a DEMI system which utilizes Submersed Vortex Cavitation technology and PLM-403-SUB detergent. This system efficiently cleans the parts, removing residual resin from the printing process. However, a final rinse step is necessary to prepare parts for curing and/or additional cleaning steps.

IPA has traditionally served as the final rinse step, but it has an incredibly low flashpoint, which makes it a hazard to any facility, and as previously mentioned, some facilities and countries will not allow IPA to be used at all in their facilities.

How to Eliminate IPA from Resin Post-Processing

To completely eliminate IPA from the resin removal workflow, PostProcess has developed AUX-400-RINSE. This organic-based rinse solution can be used as a final rinse step following processing in PostProcess automated resin removal solutions.

PostProcess conducted comprehensive testing of AUX-400-RINSE, focusing on flashpoint, drying time, safety, longevity, and material compatibility. The findings revealed that AUX-400-RINSE surpasses industry safety and performance standards and also sets a new benchmark for post-processing excellence.

The full PostProcess resin removal workflow, featuring AUX-400-RINSE, streamlines operations, reduces manual labor, and ensures consistent part quality, promoting regulatory compliance and a healthier work environment.

Pioneering a Safer Future

The development of AUX-400-RINSE highlights PostProcess Technologies’ commitment to advancing industry standards through safer and more efficient solutions. Manufacturers can improve safety, enhance environmental practices, and achieve operational efficiency by adopting IPA-free resin removal methods.

AUX-400-RINSE provides a significant reduction in overall safety hazards due to the high potential for IPA fumes to spontaneously combust at low temperatures, which poses a risk of injury to employees and creates a hazard to the overall facility’s environment. Both chemistries used in PostProcess’ resin cleaning workflow provide increased safety. AUX-400-RINSE has a 21% lower vapor pressure than IPA, reducing flammability risks, and PLM-403-SUB offers a significantly higher flashpoint of 220°F / 104.4°C compared to IPA’s flashpoint of 53°F / 11°C.

If you’d like to learn more about an IPA-free post-processing resin removal workflow, download our white paper: Eliminating IPA in Resin Cleaning.

Elastomeric resins are a class of polymer materials known for their elasticity, which allows them to regain their original shape when distorted. Examples include natural rubber, polyurethane, polybutadiene, neoprene, and silicone. Consumer goods, automotive, and industrial are a few of the key industries using elastomeric resins in the market.

The number of elastomeric resins is also growing rapidly, with 45 different types and more to come in the future. However, like other 3D printed materials, elastomeric resins pose significant challenges in the post-processing step. It can be difficult to remove the uncured resin without impacting the cured resin. Solvent soaks, such as isopropyl alcohol (IPA) or tripropylene glycol monomethyl ether (TPM) can alter elastomeric properties, causing breakage, swelling, cracking, or loss of elasticity.

Introducing PostProcess Elastomeric Resin Removal Solution, PLM-501-SUB™

To address these challenges, PostProcess Technologies has created a new elastomeric resin removal solution featuring an all-new additive-specific chemistry, PLM-501-SUB. This is an organic-based resin removal solution for VAT-based 3D-printed elastomeric parts. PLM-501-SUB is specifically formulated to remove uncured resin from elastomeric materials while minimizing swelling, damage, or changes to mechanical properties.

This full-stack solution integrates hardware, software, fixtures, and proprietary chemistry to remove resin from many 3D printed plastic materials, effectively cleaning parts from elastomeric materials while minimizing overall part damage.

PLM-501-SUB is designed for use in PostProcess’ DEMI 400, X 520, 800, and 900 Series solutions. These solutions provide a completely IPA-free elastomeric resin removal system, integrated with PostProcess hardware, AUTOMAT3D software, allocated fixtures, PLM-501-SUB, and rinsing with AUX-400-RINSE.

After elastomeric parts are submerged in PLM-501-SUB, they can then be rinsed with PostProcess’ AUX-400-RINSE if a final rinse step is necessary before they are dried and/or cured.

Why Choose PLM-501-SUB?

Odorless and Organic: PLM-501-SUB™ is an odorless, organic solution with a 30% longer lifespan compared to IPA and TPM.

Enhanced Safety: It provides a safer alternative to solvent soaks like IPA, with a high flashpoint (237°F / 115°C) to significantly reduce flammability risks. Unlike IPA, it does not require explosion-proof or ATEX-certified equipment.

Efficiency and Speed: Elastomeric resin is removed within 5-7 minutes when components are submerged in PLM-501-SUB™ using a PostProcess SVC solution. This eliminates the need for manual labor and achieves superior efficiency, with 35-38% longevity in terms of resin by weight.

High-Quality Output: By integrating PLM-501-SUB™, manufacturers can protect elastomeric parts from swelling or cracking, resulting in a higher quality end-product and increased throughput production of quality parts.

Seamless Integration with PostProcess Solutions

PLM-501-SUB is designed for seamless integration with PostProcess’ DEMI 400, X 520, 800, and 900 Series solutions, providing a more efficient and safer production process.

Eliminating solvent soaks and integrating PLM-501-SUB in a PostProcess solution will prevent swelling or cracking of elastomeric parts, boosting the production throughput of high-quality end products, while eliminating safety concerns.

PLM-501-SUB is the superior solution for PostProcess systems with its ability to streamline workflows, improve part quality, and increase production efficiency.

At PostProcess, we continue to push the boundaries in the additive manufacturing industry. Our latest innovations, DEMI X 520™ for Resin Removal and DEMI X 520 for Dental Resin Removal, expand our post-processing offerings and provide the world’s only IPA-free resin removal solution.

The DEMI X 520 series elevates post-printing workflows, combining intelligent software capabilities, robust hardware features, and specially formulated chemistry to achieve optimal IPA-free resin removal for 3D printed parts. These solutions extend the PostProcess Submersed Vortex Cavitation™ portfolio and introduce brand new Axial Flow Technology™ to deliver enhanced features that provide a simple, personalized and full-stack post-processing experience.

Customizable Software for Seamless Operation

The DEMI X 520 series solutions are equipped with our AUTOMAT3D® software to seamlessly guide users through the entire processing cycle.

This AUTOMAT3D® software is completely customizable, allowing users to set their own time, temperature, and agitation for their particular application. These tailored experiences allow for a consistent, efficient, and error-free operation. Plus, users can also conveniently store recipes for future use.

The difference between the two solutions? The DEMI X 520 for Resin Removal is equipped with software designed specifically for dental resin removal. The DEMI X 520 is designed for all other resin applications, including plastic resins and elastomeric resins.

Cutting-Edge Hardware & Fixtures

The DEMI X 520 series offers cutting-edge hardware and fixtures that guarantee unparalleled consistency.

This includes:

• An automated parts lift to protect parts from over-exposure to chemicals and enhance operator safety.
• Specific resin removal fixtures designed to ensure optimal part processing, whether parts are processed directly on the build platform or in batches off-platform.
• Brand new Axial Flow Technology, to give users the ability to adjust flow and optimize performance, resulting in consistent, high-quality finished parts.

IPA-Free Chemistry

The rising safety and environmental concerns of isopropyl alcohol (IPA) in traditional post-processing methods have created a need for alternatives in the industry. At PostProcess, we strive to create solutions that are completely IPA-free.

The DEMI X 520 series uses a combination of PLM-403-SUB detergent and AUX-400-RINSE, offering a safer and more efficient alternative to IPA.

Engineered for operator well-being, this proprietary chemistry produces low odors and enhances safety for technicians with high flashpoints of PLM-403-SUB (220°F / 104.4°C) and AUX-400-RINSE (102°F / 38.8°C), significantly reducing the risk of flammability. The biocompatible PLM-403-SUB detergent also ensures seamless and quick resin removal, with most cycles completed in less than 10 minutes.

The addition of AUX-400-RINSE as the final rinse step in the workflow, eliminates any need for IPA in the resin removal process.

By combining intelligent software, cutting-edge hardware, and safer chemistry, these solutions will transform your 3D printing workflows.

Both solutions in the DEMI X 520 series ensure unparalleled consistency through validated workflows, enabling high-quality, repeatable cycles. These innovations translate into increased throughput and productivity, setting a new standard for precision and reliability in resin removal technology.

Explore the future of resin removal with the DEMI X 520 series and step into a new era of enhanced safety and streamlined resin removal.