by Cassandra Balentine
Sustainability goals in the manufacturing industry contribute to the trend of using UV-curing systems for three-dimensional (3D) printing processes—especially among additive manufacturing (AM) methods that work with resin.
“Post curing is a crucial step in the AM process, especially when working with photopolymer resins. After a 3D printed part is built, typically in processes like stereolithography, digital light processing, or material jetting, it is not yet fully cured and often lacks the necessary mechanical strength or stability. Post-curing involves exposing the printed part to additional UV light, which further reacts with the photopolymer resin, enhancing the part’s material properties,” explains Eugene Mikhaylichenko, director of sales and marketing, Uvitron International. “This step is critical for achieving the final material characteristics required for the part’s intended application, such as increased strength, durability, and thermal stability.”
Recent analysis by Exactitude Consultancy indicates that the global 3D printing in UV resins market is anticipated to grow from $2.08 billion USD in 2023 to $2.65 billion USD by 2030, at a compound annual growth rate of 3.5 percent during the forecast period.
According to Exactitude Consultancy, the ongoing advancements in 3D printing technologies play a critical role in propelling the growth of UV resin-based 3D printing. “The continuous evolution of printer hardware, software, and curing processes represents a dynamic landscape of industry innovation,” notes a press release on the report.
The “Green” Edge
Within AM technologies, the adoption of UV-cured systems marks a significant stride towards more sustainable manufacturing practices, according to Mikhaylichenko. This is because the method’s core advantage lies in its precise material utilization and energy efficiency, “which are pivotal in reducing the environmental impact of manufacturing processes.”
One critical aspect of UV-cured AM is its material efficiency. Mikhaylichenko explains that the process involves using photopolymer resins that are cured with UV light, allowing for highly accurate and controlled application. “This precision significantly minimizes material wastage, a common drawback in traditional manufacturing, particularly with subtractive techniques. In contrast, UV-cured AM deploys material judiciously, ensuring that only the required quantity is used. This not only conserves resources but also reduces the waste generated, aligning with the principles of sustainable manufacturing.”
A reduction of heat also makes UV-curing arguably greener compared to alternative traditional methods. “Most traditional 3D print methods involve heat. Power consumption is lower in UV-cured AM versus heat-based technologies. Also, AM in general is more material efficient than traditional, subtractive methods,” shares Stacy Hoge, Phoseon marketing manager, Excelitas Technologies Corp.
Mikhaylichenko points out that traditional manufacturing methods often rely on high-temperature processes, which are energy intensive and contribute substantially to the carbon footprint of production. “UV curing, in comparison, is a low-temperature process. It consumes considerably less energy, thereby reducing the overall environmental impact. This lower energy requirement translates into reduced carbon footprint, making UV-cured AM a more sustainable alternative in the manufacturing industry.”
Increased Interest
Mikhaylichenko feels that the burgeoning interest in UV-cured AM is becoming more pronounced, “a trend propelled by both its environmental advantages and technological progress.”
AM processes that require a long printing cycle or use heat-sensitive materials benefit the most from UV LED curing, believes Hoge.
With a reliable UV LED light source, Hoge adds that customers can run a stable process for a long time—some printing cycles can be more than 48 hours. “The UV LED printing process offers the highest efficiency, printing accuracy, and most yield to fulfill the end customer’s stringent requirements. LED technology also allows users to cure heat-sensitive materials, offering new revenue opportunities for printers.”
Mikhaylichenko explains that as industries become more conscious of their ecological impact, there’s a concerted effort to adopt manufacturing processes that are more environmentally benign. “In this landscape, UV-cured AM emerges as a standout choice, primarily due to its efficiency in material usage and energy consumption. The shift towards UV-cured AM is largely fueled by a growing, industry-wide commitment to reducing environmental footprints. This technology aligns well with sustainable manufacturing goals, thanks to its ability to significantly cut down on material waste. Traditional manufacturing often leads to excess material being discarded, but UV-cured AM circumvents this issue through its precise application of photopolymer resins, ensuring that only the necessary material is used and wasted resources are minimized.”
Another catalyst for the increased adoption of UV-cured AM is the continual enhancement of the technology itself. “Recent advancements in UV curing have not only increased its efficiency but also made it more cost effective. These improvements have broadened the appeal of UV-cured AM, making it a viable and attractive option for an array of sectors. As a result, we’re witnessing a significant shift in manufacturing preferences, with more industries leaning towards UV-cured AM as their go-to choice,” shares Mikhaylichenko.
Hoge also sees increased demand for UV-cured AM, specifically the use of UV LED curing technology “because it offers a consistent reliable process that can run on a range of heat-sensitive materials for a long period of time.”
Regulatory Considerations
The role of government regulations is also shaping the adoption and evolution of UV curing in AM. “As environmental policies across the globe become more rigorous, there is an observable shift in the manufacturing sector towards embracing cleaner and more sustainable technologies. UV-cured AM is at the forefront of this shift, largely due to its environmentally friendly characteristics,” stresses Mikhaylichenko.
The tightening of environmental regulations has effected the manufacturing industry’s trajectory. “These policies are not just advisory in nature, they are actively reshaping industry norms and practices. UV-cured AM, known for its minimal environmental impact, aligns well with these evolving regulatory standards. As a result, there is a marked increase in the adoption of UV-cured AM processes, spurred on by the need to comply with stringent environmental guidelines,” offers Mikhaylichenko.
These government regulations serve as pivotal catalysts for technological innovation in the realm of AM. “They are not only encouraging but necessitating the shift towards technologies that are ecologically sound. UV curing, with its reduced waste and energy consumption, is a prime example of such technology. This regulatory environment pushes manufacturers to invest in and adopt UV curing, thereby advancing the cause of sustainable manufacturing practices,” adds Mikhaylichenko.
While Hoge feels that expanding government regulations are not presently influencing the demand for UV curing for AM, she believes it will likely morph as energy efficiency and climate change-related programs intensify.
Future Outlook
The future of UV-cured AM is promising due to significant scientific advancements in UV LED curing technology. “This technology has evolved rapidly, with improvements in UV LED light sources that offer greater intensity and more efficient curing processes. These advancements allow for faster curing times and greater control over the curing process, which is critical for achieving consistent mechanical properties in 3D printed parts,” says Mikhaylichenko.
Additionally, advancements in photopolymer chemistry enable the development of new resins optimized for UV curing. Mikhaylichenko says these resins are designed to respond more effectively to UV light, resulting in improved physical properties such as increased strength and higher temperature resistance. “This is particularly important for applications in industries like aerospace and automotive, where material properties are critical.”
The versatility of UV-cured AM is also expanding its applications into various industries. In the medical sector, for example, Mikhaylichenko says UV-cured AM is used to create customized prosthetics and dental implants with improved biocompatibility and strength. In the automotive industry, it’s employed for the rapid prototyping of complex parts, reducing development time and costs. Furthermore, in electronics, UV-cured AM is instrumental in producing intricate components with high precision.
Mikhaylichenko also sees a growing trend towards customization and small-batch production in various sectors, and UV-cured AM is ideally suited for this shift. “Its ability to produce complex geometries without the need for tooling aligns with the industry’s move towards more personalized and on-demand production models.”
Hoge believes that UV curing for AM will trend upwards in the near future, along with the AM sector as a whole. “As more research and development is done to push the performance of UV-cured resins, the future will offer the ability to print on a wider range of materials and substrates enabling new applications.”
UV for AM
Post curing is a crucial step in the AM process when working with photopolymer resins. Using UV light here helps achieve the final material characteristics required for the part’s intended application, such as increased strength, durability, and thermal stability.
The use of UV curing in AM is also known to bring cost and environmental benefits, which is leading to increased demand in the space.
Apr2024, Industrial Print Magazine
