Achieving true production versatility with the PSLA 270

3D printer hardware is at the core of an AM service’s offering, so it’s vital that this hardware is up to the highest standard, delivering on speed, quality and consistency. As service technicians and 3D printer operators across the industry will know—particularly those who have been in the AM industry for a long time—3D printers have advanced tremendously in recent years, not only leading to higher quality prints with less input, but also improving the bottom line for AM services, who can take on more jobs and increase throughput knowing their machines are working reliably.

In the resin AM sphere, this evolution is epitomized in 3D Systems’ projector-based stereolithography (PSLA) technology. First introduced in the fall of 2024, the technology is a hybrid resin 3D printing approach that combines the precision of laser-based SLA with the speed and throughput of projector-based photopolymerization. The PSLA 270, the first PSLA-based machine launched by 3D Systems, integrates dual HD projectors that cure resin layers from above. This top-down approach comes with a number of benefits, including a mid-sized build area (with a max build size of 242 x 265 x 300 mm), and parts that are supported within the resin and which are not impacted by the distorting effects of gravity.

Turning to its specific capabilities, the PSLA 270 3D printer can reach print rates of up to 38mm per hour while delivering a resolution of 90 µm and surface smoothness of <RA 0.25 µm. This translates to printed parts that have the quality of injection molded components—all without the need for sanding or polishing—delivered at a significantly faster speed than conventional SLA.

Versatile applications

From the perspective of AM services, the PSLA 270 is a versatile machine that can fulfill a range of applications for various industries. This utility is owed in large part to the system’s compatibility with various resin materials. In fact, this was a key point for 3D Systems in the development of the hybrid system: it wanted to offer a productive, mid-frame solution that could use its Figure 4 portfolio of engineering and production-grade resins, including rigid, tough and durable materials with properties suitable for functional applications.

These materials, in combination with the PSLA 270’s unique capabilities, make the solution viable for printing functional prototypes (suitable for fit, windtunnel and thermal tests, among others), manufacturing aids and tools (including jigs & fixtures, carbon fiber tooling, eggshell molding, PU casting and investment casting), and end-use parts (particularly when customization and small-to-medium batch sizes are required).

Prototyping

In the case of prototyping, 3D Systems offers a range of materials whose properties meet the diverse needs of different industries and applications. For example, materials like Figure 4 PRO-BLK 10, a production-grade resin with thermoplastic-like mechanical properties and excellent environmental stability; Figure 4 Rigid Gray, a high-contrast resin with balanced thermal and mechanical properties; and Figure 4 FLEX-BLK 20, a flexible impact-resistant resin with long-term environmental stability, are ideal for functional prototypes that must match the properties of final components for form and fit testing.

Other materials, like Figure 4 HI TEMP 300-AMB and Figure 4 Tough FR V0 Black, offer the needed temperature resistant properties (with HDTs of over 300°C) required for thermal testing. In the case of HI TEMP 300-AMB, for example, users can manufacture and test prototypes for HVAC systems, consumer appliances, motor enclosures and more—all without the need for a secondary thermal post-cure process.

3D Systems also highlights Figure 4 Rigid Composite White resin as an ideal candidate for parts that require wind tunnel testing. The material, a composite with high stiffness and excellent smoothness with minimal post-processing, is thus suitable for product development and testing in industries like motorsport, consumer automotive and aerospace, where wind tunnel testing is required.

Manufacturing aids

Many of these Figure 4 resins are also viable for tooling applications, including jigs, fixtures and assembly aids. In particular, Figure 4 FLEX-BLK 20, Figure 4 HI TEMP 300-AMB and Figure 4 Rigid Composite White offer users the strength, resistance and smoothness that manufacturers need. For AM services, this capability expands what can be offered to customers as well as enables the in-house production of tools and aids that can streamline their own production workflows.

3D Systems’ PSLA 270 is also compatible with Figure 4 EGGSHELL-AMB 10, a rigid resin engineered for the production of sacrificial tooling for casting silicone and other elastomeric materials, as well as metals and ceramics. By 3D printing eggshell molds directly, AM services can offer customers silicone prototypes or bespoke elastomeric components without the high costs associated with conventional tooling.

Similarly, the PSLA 270 can rapidly and cost-efficiently iterate patterns for PU casting in cases where injection molded parts are required. As 3D Systems sums it up: “PU casting offers a cost-effective way to produce 1 to 50 parts that accurately replicate injection molded parts”. For this application, Figure 4 PRO-BLK 10 and Figure 4 Rigid Gray are recommended.

End-use parts

With a range of production-grade materials at their disposal, AM services working with the PSLA 270 can also produce end-use parts for customers. Leveraging 3D printing for final components brings with it greater design freedom and production agility, as customers can economically realize custom products, one-off replacement parts or low-volumes of products. That’s not to mention the isotropic strength and high-quality surface finish specifically enabled by 3D Systems’ PSLA technology.

For end-use applications on the PSLA 270, 3D Systems recommends Figure 4 PRO-BLK 10, suitable for parts like motor housings, connectors, snap-fits and automotive interior components; Figure 4 Tough FR V0 Black, ideal for aircraft electrical connectors, knobs, grommets and spacers, as well as flame retardant parts for trains and buses; and Figure 4 Rigid Gray, good for applications like housings and covers, small consumer products and parts needing painting, plating or laser-etching.

Production without compromises

Overall, whether used for prototyping, tooling or end-use production, the PSLA 270 is designed to accelerate lead times, minimize costs and eliminate design and production constraints associated with traditional manufacturing processes and less advanced 3D printing systems. The new platform marks a distinct step forwards in the capacity of resin 3D printing technologies, allowing end users to realize high-quality parts more efficiently without compromising on critical factors like mechanical properties, thermal stability and surface quality.

For AM services in particular, which serve a broad range of end-users, from product designers and industrial firms to automotive and aerospace companies, having such a versatile platform in-house can enhance productivity and capacity significantly. To learn more about the PSLA 270 platform, its compatible materials and possible applications, read 3D Systems’ Application Guide for its new system, which clearly outlines how the PSLA 270 can transform everything from concept to final production.

This article was originally published in VoxelMatters’ VM Focus Services AM eBook. Read or download the full eBook for free at this link.