Carbon Digital Light Synthesis (DLS)

Manufacture production-ready parts with extraordinary mechanical properties, resolution, and surface finish utilizing our Carbon DLS (CLIP) process.

Carbon DLS with CLIP Technology

We were chosen by Carbon to be one of the first 3D printing service bureaus in the world with the ability to 3D print prototypes and production parts from the Carbon DLS M2 printers. The Carbon DLS CLIP technology provides parts from amazing elastomeric and rigid materials that match or exceed injection molding properties, part finish and quality. DLS is a true digital manufacturing technology not just for prototyping, but for the production of customized parts and serial production. With Carbon CLIP technology, we help our clients design, prototype and print functional parts for production applications in the medical, aerospace, industrial, consumer, and automotive markets.

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Carbon DLS 3D Printing Process

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Carbon Digital Light Synthesis (DLS) is the photochemical process using both light and oxygen to build parts. DLS works by projecting UV images generated by a digital light projector, through an oxygen-permeable window in a reservoir of UV curable resin. After parts are built continuously layer by layer in 25 to 100 micron layers, parts go through a wash or rinse process. After all excess material is rinsed away, supports are removed and parts go into ovens for final curing which gives the parts their mechanical properties and strengths.

The result is production-ready parts with extraordinary mechanical properties, resolution and surface finish produced in days not weeks. Carbon DLS is unique from the other 3D printing technologies, like SLA, FDM and MFJ, as it uses thermoset materials (e.g., plastics/composites)  and though it can be used for prototyping exceptional parts, it is really geared for repeat production builds.

Carbon DLS has many benefits:

  • Wide range of elastomeric and rigid engineering-grade materials
  • Biocompatible and sterilizable materials
  • Reduce time to market
  • Isotropic parts, air-tight and leak-proof
  • Outstanding surface finish
  • Smart equipment for industry 4.0

Carbon DLS parts are best used for:

  • End-use production parts
  • Digital Inventory for on-demand production
  • Part consolidation
  • Complex, organic, generative designs
  • Foam replacement parts

 

Design Without Restriction

Learn how we worked with NASA Johnson Space Center to create four Carbon DLS additive manufactured components used to control and fly the Seeker Robot in space for the NASA Seeker program.

 

 

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From design to prototype and production, our team of engineers is ready to help bring your idea to life.

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Carbon DLS Materials


The Carbon 3D materials available for 3D manufacturing with the Carbon DLS process were designed to rival current thermoplastic materials. Parts will be tough, resilient, isotropic and machinable. Each material was engineered to provide similar properties to production injection molding materials like acrylonitrile butadiene styrene (ABS), glass-filled nylon, Polypropylene (PP), and thermoplastic polyurethane (TPU).

Available Materials:

Learn more about the available Carbon DLS Materials.


Carbon DLS Equipment

The Carbon M2 Printer has a build volume measuring 7.4″ x 4.6″ x 12.8″ (189mm x 118mm x326mm). The M2 is ready for production with high-reliability hardware, expansion port for smart accessories, and compatible workflow automation for any production configuration.

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We use Carbon’s Smart Part Washer and MMD (Meter/Mix/Dispense) equipment to automate labor-intensive washing and dispensing of materials which in turn reduces costs for production runs. The Smart Part Washer consistently cleans parts with next-generation software delivering automatic, part-specific wash protocols, process control data for part traceability, and regular software updates. The MMD machine reduces material costs with bulk material packaging, reduced resin handling, and improved reliability and quality for production with automated, accurate material dispensing.


Carbon DLS Build & Design Guidelines

Carbon DLS offers amazing part details and quality, but each 3D printing technology ranges on what size features it can build see below for best standard practices

  • Build Layers = Standard is 0.004” (100 micron) but can reduce to 0.001”-0.002” (25-50 micron)
  • Minimum Walls Thickness & Feature = 0.040” (1mm)
  • Standard Finish = Level 1 Support Removal Finish (available custom finishes)
  • Standard Lead Time = 3-5 days
  • Tolerances = +/- 0.005” for first inch then +/- 0.002” per inch thereafter
  • Inserts = Preferred for threads; install in post-processing with heat stake or adhesives
  • Holes = Drill, Ream, and Tap (Print threads then chase or ream in finishing)

What Our Partners Are Saying

I truly enjoy working with the team at The Technology House - it has been a true partnership. Their extensive knowledge in product development and manufacturing is beneficial not only to Carbon, but also to end customers looking for manufacturing help. The Vitamix success story with Carbon is one proof point of their incredible work. You won't be disappointed when working with The Technology House!

- Dana McCallum, Head of Market Development at Carbon, Inc.

I have partnered closely with TTH for over a year, and working with them has been a wonderful experience. Their entire team is always pleasant to work with, their project managers are incredibly knowledgeable, and their attention to quality and timeliness is best in class. I simply cannot recommend them highly enough for any project big or small.

- Jordan G., Additive Manufacturing Professional

Design Without Restriction

See how we partnered with Vitamix and Carbon to redefine what's possible. We took a legacy, six-piece, injection-molded part design and turned it into a new, one-piece, 3D-printed part.

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Our integrated approach to design, prototyping, and production allows you to bring your concept to market faster, more cost-effectively than virtually anyone else.

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