CADworks3D utilizes Digital Light Processing (DLP), a resin-based 3D printing technology.

It operates by using a projector to shine light onto a vat of liquid photopolymer resin, which hardens when exposed to light. The projector projects the shape of each layer of the object being printed, and as the build platform moves, the printer adds layer after layer until a solid 3D object is complete. Once completed, the object is cleaned and further cured with UV light. This method is quick, precise and efficient, ideal for creating highly detailed microfluidic devices.

3D printing and traditional methods like photolithography each have unique strengths, and rather than replacing photolithography, 3D printing acts as a complementary tool.

3D printing provides a fast, cost-effective way to accelerate the prototyping stage of device development. Researchers can quickly create and test designs, modify them as needed, and iterate rapidly without the time and expense involved in traditional fabrication. Once a design is finalized and optimized through 3D printing, a researcher can choose to transition to photolithography.

The key differences between Digital Light Processing (DLP) and Stereolithography (SLA) 3D printing lie in how they cure the resin and their impact on print speed, resolution, and precision.

DLP uses a digital projector. The projector shines light in the exact pattern of a layer, curing an entire layer of resin instantly.
SLA uses a laser. The laser moves point-by-point to trace and cure the shape of a layer over a period of time.

Speed and Efficiency
Since DLP cures an entire layer at once, it is significantly faster than SLA. For microfluidic devices that involve more detailed, intricate designs, DLP’s speed advantage can be substantial, especially during the prototyping phase where multiple iterations are needed quickly.

Resolution and Accuracy
DLP’s light projection technology creates consistent curing across each layer. This helps to ensure uniformity in the dimensions of the channels and other features, reducing variations that can negatively impact fluid flow in microfluidic devices. SLA, while precise, may introduce slight inconsistencies in complex features due to the point-by-point tracing of the laser.

Surface Finish
Both DLP and SLA can produce smooth surfaces – important for microfluidic devices involving fluid flow. However, DLP can sometimes offer better surface finishes in small, intricate parts because the entire layer cures at once without overlapping laser traces.