Optically Clear SLA
Optically Clear SLA
As part of our range of rapid prototyping and ALM services, Malcolm Nicholls Limited (MNL) currently offer SLA modelling on 2 x SLA 5000 and 2 x SLA250 systems. One SLA250 system has Ultra-High-Resolution build capability, building at just 0.05mm layer thickness, with a laser spot size of only 0.075mm dia. Utilising this technology, components with very fine detail, such as fine legends, threads, feather-edges and thin wall sections for instance, can faithfully be reproduced from CAD. In comparison, our standard layer thickness is 0.1mm with a spot size of 0.4mm dia.
All of our systems are operating with the WaterShed XC 11122 clear epoxy resin, which produces strong, tough, extremely water- resistant, ABS-like components, which are near colourless.
MNL offer a range of finishing levels on our SLA components, from our Level 1 (supports removed and optional sandblast) to our C2 Level, which is polished on all surface, with an optional lacquer coating.
The general tolerance on the standard build resolution is +/- (0.1+0.1%)mm and with the Ultra High Resolution, +/- ( 0.05+0.05%)mm. Consequently when producing complex assemblies, some parts containing fine detail can be manufactured using the high resolution laser and parts of lesser detail, can be produced using the standard resolution laser. Obviously the finer layers take longer to build and consequently cost slightly more, but having this option, MNL can offer the most cost effective route in achieving your requirements, which is a great advantage.
Malcolm Nicholls rear lights prototyped for Jaguar Land Rover
Malcolm Nicholls rear lights prototyped for Jaguar Land Rover
This methodology is best illustrated using a rear light cluster that we produced for Jaguar Land Rover, as an example. The complex prism arrangements of the rear of the lenses were manufactured using the High-Resolution laser in conjunction with a lacquered C2 finish. The lamp bezels and housings were manufactured using standard resolution, as these were simpler surfaces and more easily accessible to hand-finishing. Some of these parts, like the rear housing, were simply spray painted, whilst other components had various electro-plated chrome finishes, completing the overall visual effect.
In short, the whole assembly was produced using only SLA, with no secondary processes like vacuum casting, keep costs down to a minimum. The red and amber lenses were polished SLA finished with tinted lacquer. The final rear lamp cluster did change a little visually during its further development, but the finished product can be seen on our roads today.
Other applications MNL have provided clear SLA components for have included, clear housings for pumps, so with the addition of polystyrene balls water flow can be visually assessed. Clear gearbox housings, to check oil throw and clearances and of course, prototype glass components, like medical instruments, drinking glasses, bottles, light-pipes and lamp lenses.
