EnvisionTEC, now operating as ETEC under Desktop Metal, has established itself as a leader in additive manufacturing, particularly within high-precision applications. Since its first patent submission in 1999, the company has consistently innovated 3D printing solutions, offering a diverse portfolio of printers and proprietary materials.
These advanced systems cater to demanding industries such as jewelry, dental, and medical device manufacturing, where exceptional accuracy, surface finish, and intricate detail are paramount. EnvisionTEC’s technologies are designed for both rapid prototyping and the production of end-use parts, providing robust solutions for various professional needs.
EnvisionTEC 3D Printing Solutions: An Expert Guide
Digital Light Processing (DLP) Technology
Digital Light Processing (DLP) is a core technology employed by EnvisionTEC, utilizing a high-definition projector to cure photosensitive liquid resins layer by layer. This method projects an entire image of a layer at once, significantly speeding up the printing process compared to traditional stereolithography (SLA) which uses a laser to draw out each layer sequentially.
EnvisionTEC’s DLP printers, such as the Perfactory series, leverage Texas Instruments DLP projectors to solidify photopolymer voxel by voxel. This ‘voxel’ technology, where each volumetric pixel can be as small as 16µm x 16µm x 15µm, contributes to superior surface quality by eliminating visible layering or ‘stepping’ artifacts.
The company also developed Continuous Digital Light Manufacturing (cDLM) technology, launched in 2016, which further enhances DLP printing speeds. cDLM allows the build plate to move continuously in the Z-direction, enabling uninterrupted curing of photopolymers and dramatically reducing print times for certain applications.
DLP systems typically achieve dimensional tolerances of ±0.1–0.2 mm, with some modern printers reaching ±0.1 mm for intricate details. EnvisionTEC’s patented contour grayscale software further refines resolution, boosting native XY resolution from 93 microns to 60 microns on some cDLM models, ensuring smoother surface finishes and extreme accuracy.
High-Precision Jewelry Wax Printing
| Parameter | EnvisionTEC D4K Pro Jewelry | Envision One cDLM Dental | DLP Standard Tolerances |
|---|---|---|---|
| Build Envelope (mm) | 148 x 83 x 110 | 180 x 101 x 85 | N/A |
| XY Native Resolution | 50 µm (25 µm enhanced) | 93 µm (60 µm enhanced) | ±0.1–0.2 mm (100-200 µm) |
| Z Resolution (Dynamic) | 1 µm | 15 – 150 µm | ±0.1–0.2 mm (100-200 µm) |
| Print Speed | Fastest for standard DLP | Up to 80 mm/hour | Material dependent |
| Compatible Materials | WIC100G, QView, castable resins | E-Model Light, E-Dent 400 MFH C&B, E-Denture 3D+ | Photopolymer resins |
EnvisionTEC has been a prominent provider of 3D printing solutions for the jewelry industry since 2003, offering high-resolution printers specifically designed for creating intricate wax patterns for investment casting. These systems enable jewelers to produce highly detailed models with fine features, eliminating the need for painstaking hand carving.
The D4K Pro Jewelry printer, for instance, offers an XY native resolution of 50 µm, with a patented enhanced XY resolution of 25 µm, and a Z resolution of 1 µm. This level of detail is crucial for capturing the delicate intricacies required in fine jewelry designs, ensuring crisp edges and smooth surfaces.
EnvisionTEC’s castable resins, such as the WIC100G and EC series, are formulated to provide excellent burnout properties, which is critical for successful investment casting. WIC100G, a nano-wax content resin, ensures a clean burnout using standard wax burnout cycles and regular gypsum investment, preventing issues like excessive expansion or pressure during degassing.
The evolution of these materials, including the EC3000 with 55% wax content and Easy Cast 2.0 C with approximately 90% wax content, aims to make 3D printed patterns cast as easily as traditional wax patterns. This advancement allows for the direct printing of entire spruing trees, streamlining the casting process and reducing labor-intensive steps.
Medical and Dental Resin Printers
EnvisionTEC’s 3D printing solutions are extensively utilized in the medical and dental sectors, providing high-accuracy and biocompatible materials for a wide range of applications. The company’s dental and medical division was rebranded to Desktop Health in 2021, though the underlying EnvisionTEC technologies remain foundational.
Printers like the Envision One cDLM Dental are designed for high-volume production in dental labs, capable of printing multiple orthodontic arch models in under 15 minutes. These systems support various dental resins, including E-Model Light, E-Dent 400 MFH C&B for crowns and bridges, and E-Denture 3D+ for denture bases, all of which are FDA-approved.
For medical applications, the EnvisionTEC 3D-Bioplotter series is a benchmark system in bioprinting, trusted by research institutions worldwide. It offers exceptional precision, with X-Y repeatability down to 1 µm, and supports diverse biomaterials for tissue engineering, scaffold fabrication, and organ models.
Recent advancements include a Print and Cure printhead for the 3D-Bioplotter, which integrates printing and immediate curing to maintain precision and stability of delicate structures. EnvisionTEC also offers medical-grade materials like UV Silicone 60A MG and biodegradable PCL polyester for implantable devices, with FDA Master Files available.
Smooth Surface Finish and High Resolution
Achieving a smooth surface finish and high resolution is a hallmark of EnvisionTEC’s 3D printing technology, particularly with its DLP and cDLM systems. The voxel-based projection in DLP inherently minimizes the ‘stair-stepping’ effect often seen in other layer-by-layer additive processes, resulting in parts with superior aesthetic quality.
EnvisionTEC printers are known for producing parts with native resolutions ranging from 30 to 100 µm, with some models achieving accuracy down to 0.03 mm. This high resolution, combined with advanced material properties, allows for the creation of fine details and thin walls, crucial for intricate designs in jewelry, dental, and medical fields.
Materials like E-Glass 2.0 are specifically formulated to deliver excellent surface finish and feature resolution, ideal for simulating clear plastics. The company’s focus on material science ensures that resins not only print with high fidelity but also possess the necessary mechanical properties for their intended applications, from castable waxes to durable engineering plastics.
The Envision One cDLM, for example, boasts an XY resolution of 93 µm, with an enhanced resolution of 60 µm using contour gray scaling, and dynamic Z resolution from 25 µm to 150 µm. This precision, coupled with minimal post-processing requirements, significantly reduces manufacturing costs and accelerates production timelines.
High-Resolution Desktop 3D Printing
EnvisionTEC offers a range of high-resolution desktop 3D printers that bring industrial-grade precision to smaller footprints. These machines are designed for professionals requiring exceptional detail and accuracy without the need for large-scale industrial systems.
The D4K Pro stands out as a professional-grade desktop 3D printer, featuring a 4K UV DLP projector for stable performance and fine detail. It offers a build envelope of 148 x 83 x 110 mm and an XY native resolution of 50 µm, making it suitable for demanding applications in jewelry and dental fields.
Another notable desktop offering is the Envision One cDLM, which combines a compact size with advanced continuous digital light manufacturing technology. This printer provides a build volume of 180 x 101 x 85 mm and a print speed of up to 80 mm/hour, making it one of the fastest standard DLP printers available.
These desktop printers are compatible with a wide array of EnvisionTEC’s proprietary resins, allowing for versatility across various applications. The user-friendly interfaces and integrated software, such as Envision One RP, simplify model preparation, automatic support generation, and mesh healing, making these powerful tools accessible to a broad range of users.