Photocentric: Resin 3D Printing Large Panels with Complex Geometries and Zero Warping

Photocentric was commissioned by a major automotive supplier to produce 10 large containers for holding electrical components in test vehicles.After evaluating production options, 3D printing was identified as the only feasible method to meet the deadline.

However, using a standard large-format laser SLA printer was ruled out due to high costs, slow production speeds, and concerns over the functionality of the parts for their intended use.

Quick Facts

Materials
Ultracur3D® EPD 2006

Partner
Photocentric

Technology
LCD resin

Why Forward AM & Ultracur3D® EPD 2006?

AM offers accelerated time to market
Competitive production pricing
Innovative process ensures warp-free printing

Photocentric specializes in manufacturing 3D printers, parts, and polymers, with a focus on large-format 3D printing. Founded in 2002, the company operates from a 66,000-square-foot facility in Peterborough, UK. Their commitment to innovation is driven by a dedicated team of engineers, supported by expert chemists, designers, and software developers, all working to create practical 3D printing solutions that improve manufacturing processes. Collaborations with partners like Forward AM help advance materials and technologies that enhance the efficiency, scalability, and sustainability of 3D printing.

Challenge: Developing and producing highly accurate and cost-effective large containers for test vehicles

Even though the design supplied by the client followed AM design guidelines, it still needed some optimization. The original version would have warped during production, but Photocentric was given the freedom to tweak the non-facing surfaces within tolerance of 18 key measurements. This allowed them to print one of the largest 3D prints ever using Ultracur3D® EPD 2006 and the Liquid Crystal Titan by Photocentric.

The process looked like this:

Step 1: Design for AM

Photocentric optimized the design so it met external dimensions within tolerance of 18 critical measurements. Gyroid infill was added with a 1.2 mm by 12 mm structure, along with a design correction for shrinkage of 0.5% in XY and 0.1% in Z to ensure accuracy.

Step 2: Supports to Achieve Part Tolerance

The part was oriented at an angle of 60 degrees to minimize sudden force changes while printing. To reduce weight and break force as the surface area shifted, corners were latticed where possible. Warping was also prevented by internally latticing sections, which helped eliminate shrinkage.

Step 3: 3D Printing

Material property requirements for the enclosure were met using Ultracur3D® EPD 2006 resin. The file with supports was loaded onto Photocentric’s Liquid Crystal Titan printer and printed in 100-micron layers. The entire 3D print took 68 hours, producing 7,223 layers, with a total weight of 4,591g, including 2,062g of supports.

Step 4: Wash Process and Cure

Using the Photocentric Wash XL unit and Photocentric Resin Cleaner 30, the entire cleaning process took 15 minutes. Afterward, the part was rinsed with water for 5 minutes to remove any remaining cleaning fluid, followed by an air wand treatment to minimize the appearance of white marks. It was then placed in the Photocentric Cure XL, where it was continuously rotated for an even cure. The post-processing was completed using a combination of dual-wavelength (405nm and 460nm) high-intensity light and a temperature of 60°C, taking a total of 5 hours.

Step 5: Support Removal and Finishing

The support structures were removed from the part, leaving minor raised artifacts, which were then sanded down with an orbital sander to achieve the best surface finish.