High Resolution Rapid Prototyping
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High Resolution Rapid Prototyping | How it Works
The Envisiontec Perfactory System is unlike any other Rapid Prototyping system in that it builds the model upside-down. The model leaves the resin tank, instead of submerging into it. As it builds in 0.015-0.025mm layers, this technique leaves hardly any evidence of layer construction and thus, virtually eliminates hand-removal of obstructive materials (a major issue on very small and complex models). Consequently, the result is a resin model with a high degree of accuracy that requires practically no post finishing.

An .stl file drives the system, and the light sensitive Acrylic resin solidifies when it is exposed to the light source. Instead of using laser lighting to cure a resin, our Rapid Prototyping technique uses a standard light bulb augmented with an array of one million tiny mirrors (1280 x 1024 pixel), which are housed in the high resolution digital light processor and independently controlled by a computer. The mirrors can be positioned to reflect the light projected by the bulb onto the build platform by tilting the mirrors toward the light source to project it where it is needed to cure the resin.

By tilting the mirrors away from the light, we are able to block the light and generate a bitmap mask image of an individual .stl layer. This results in one layer being cured in one operation, rather than a single layer busily tracing around every aspect of the geometry.

Envisiontec Perfactory System Diagram

The Build Platform

The build platform consists of two pieces of ground glass. The first layer of the model attaches to the upper piece, which is fixed to the Z-height control. The other side of the model is fixed to the lower plate of glass, which constitutes the resin holding tray and helps regulate the thickness when the two plates of glass come together.

By squeezing out the excess resin, the desired layer thickness becomes trapped between them. When the light source is activated, the first model layer bonds to the upper glass plate, while the other side of the model layer is fixed to the lower glass plate. The vacuum diffuser module initiates separation of the lower glass tray from the cured layer through a sophisticated tilting mechanism that peels the glass from the model. As the plates open, they let more resin in between. The process is then repeated layer by layer. The unique up-side-down technique means the model leaves the resin as it is being built rather than submerging into it.

The Upside-down technique
Upside-down build technique

the Envisiontec Prefactory System
The Envisiontec Perfactory System.

Highly detailed ring patterns in finished models
Highly detailed ring patterns in finished models.

13 parts built in PIC100 resin