Rapid Prototyping Rapid Prototypes SLA/SLS Vacuum Casting Martello Limited

3D Systems Duraform EX plastic SLS

Rapid Prototyping Explained

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3D SLA model rocket

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StarFish Thin-Rim moulding

Martello has fifteen years experience of procuring rapid prototyping SLA and SLS parts using a wide range of technologies. We now have our own in house stereolithography machine (SLA 250) producing 3D model parts in DSM Somos Watershed 11110 resin in 0.1mm layering. We are also happy to provide expert technical advice and source the best quality, process and timescales to suit your needs if we cannot produce the parts in house. Visit our services page to see more.

Martello's SLA 250 Rapid Prototyping Machine

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Rapid Prototyping

SLA / SLS

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SLA rapid prototypes (Stereolithography)

SLS rapid prototypes (Selective Laser Sintering)

"Blue Alarm" photo reproduced by kind permission of Elmdene International Ltd

Rapid Prototyping Stereolithography (SLA) Models

Stereolithography (SLA) parts are produced by laser curing of an epoxy resin based photopolymer. The parts created are generally very crisp and rigid, but can be prone to breaking if overstressed.

Our preferred resins are DSM Somos 9120 for one-off design verification prototypes and DSM Somos 11110 or 11120 "watershed", a water resistant clear resin, for masters used for making vacuum casting moulds.N.B. When using oils with SLA parts made in 11110 the only oils that are suitable for use with the 11110 resin are silicone oils or a proprietary product from DOW chemicals called Amino Oil. You should definitely not use lithium greases, WD 40 or other regular oils.

Parts can be built at 0.1mm resolution (normal) in 11110 or 0.05mm resolution (high res) in si50 or 9120 or 11120. High resolution builds are generally more expensive but necessary for intricate, thin-walled parts and features.The expected tolerances for SLA parts are .1% - .2% or 0.1 - 0.2mm, whichever is the greater. SLA and SLS models are created from 3D .stl part files. It is important to generate good resolution .stl files with enough triangles to prevent flatting over curved surfaces. Each CAD package has different settings to adjust when you generate your .stl file, however, generally, look to set the chord height deviation / absolute faceting to 0.01mm. You can check your .stl files using a free .stl file viewer which you can download here. Alternatively, send us your CAD files in .iges/.STEP/.x_t format and we will generate the .stls ourselves.

Due to their good accuracy and definition, SLA models are our preferred RP masters for the manufacture of vacuum cast polyurethane resin prototypes. Up to 50 durable plastic prototype parts with excellent cosmetic finish can be produced from one low cost silicone rubber mould. Go to our Vacuum Casting page for more information.

Blue Alarm - finished SLA model

Rapid Prototyping Selective Laser Sintering (SLS) models

For one-off functional prototypes, SLS is a cost effective solution, providing more durable parts than SLA, albeit with not as smooth a surface and not as sharp edges. SLS is also appropriate for producing small batches of functional production parts, provided their natural colour is acceptable and they are not required to have a cosmetic finish. Duraform EX plastic is a new material which we can now offer. Parts can be black or natural and are suitable for many applications such as complex thin-walled ductwork, living hinges and snap-fit designs. The material is appropriate for low to mid-volume production or prototypes that need to display functional end-use performance properties.