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Chapter 1
DLPU025 – September 2014
Introduction to the DLP
®
3D Printer Reference Design
1.1
The DLP 3D Printer Reference Design is a full hardware design enabling 3-dimensional printing of objects
from cross-sectional images from meshed models. The reference design includes a lightweight GUI,
electrical schematics, cable assembly drawings, and mechanical drawings to create the printer.
1.2
Stereolithography
Stereolithography is an additive manufacturing method that employs a photo-curable resin. Exposing the
photo-resin to successive 2-dimensional object cross sections create the 3-dimensional objects a single
layer at a time. The resin, composed of monomers, cross-links when exposed to light of a sufficient energy
level. The cross-linking of the monomers generates a polymer chain, creating a solid material where the
resin was exposed. Stereolithography was traditionally achieved by outlining the object layer with a laser;
DLP technology allows an entire layer to be exposed at once by dynamically masking a broad light source.
1.3
How the DLP 3D Printer Reference Design Works
The DLP 3D Printer Reference Design consists of a LightCrafter 4500 evaluation module, a translation
stage driven by a stepper motor, and a microcontroller at its core. The DLP 3D Printer Reference Design
utilizes the DLP Structured Light SDK to perform the printed image creation and layer sequence for
printed objects.
1.3.1
DLP Structured Light SDK
A GUI on a host PC allows the user to upload the sliced object images to the DLP 3D Printer for storage
and exposure. The sliced layers are combined into composite images and uploaded to the LightCrafter
4500 along with their exposure sequence. The DLP Structured Light SDK prepares the layer images and
contains development modules for preparing image sequences. The SDK source code is made available
along with the GUI source code in the TIDA-00293 DLP 3D Printer design files package.
1.3.2 Photo-resins
A host of photo-resins are available in the SLA market, offered by a handful of commercial manufacturers.
Each resin has different physical properties lending themselves to specific applications. The DLP 3D
Printer is built with a 420 nm light source, which allows the use of any resin that is curable at this
wavelength or above. The resin used during the development of the DLP 3D Printer was sourced from
www.buy3dink.com
1.3.3
DLP LightCrafter™ 4500 Evaluation Module
The DLP 3D Printer Reference Design uses a modified LightCrafter 4500 projector to expose the photo-
resin. The LightCrafter 4500 is modified with a 420 nm Philips Lumileds Luxeon
®
UV LED. The projection
optics are also modified to allow the projector to focus at shorter distances, enabling higher resolution
printed objects.
1.3.4 Velmex XSlide™ Translation Stage
The printed objects form on a platform that translates on one axis only. The translation stage lowers the
build platform a precise and accurate distance for each printed layer. This reference design uses the
Velmex XSlide, which accepts NEMA 17 or 23 sized stepper motors and has integrated limit switches. The
stage is highly rigid for it's small size to ensure repeatable positioning of the build platform.
7
DLPU025 – September 2014
Introduction to the DLP
®
3D Printer Reference Design
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