As a Certified Production Partner of Carbon, Inc., Makuta is able to provide high-performance prototyping and limited production runs for small and complex parts using Carbon Digital Light Synthesis™ (DLS™) technology. This breakaway technology delivers “working” prototypes with similar quality to injection molded parts and superior structural integrity and surface finish when compared to 3D printing.

Benefits of Carbon DLS™ Technology

This fast, cost-effective technology provides a wide range of benefits:

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This fully cured Cyanate Ester compressor rotor delivers high temperature resistance, strength and stiffness, similar to 15% GF Nylon. Carbon produced this part at a fraction of the cost of the CNC alternative.
  • Eliminates the need for prototype tooling, providing significant cost savings
  • Shortens lead time and time-to-market
  • Allows design adjustments without the expense and time associated with tooling modifications
  • Produces working prototypes with superior mechanical properties compared with 3D printed parts
  • As opposed to traditional 3D printed parts, which can be weak or brittle due to the layered printing, parts produced with Carbon DLS technology are isotropic with the mechanical properties of an injection molded engineering grade resin
  • A wide range of high-performance resins are available
  • Makes customized parts (e.g., dentures, custom fit products, etc.) and limited production runs economically feasible compared with injection molding
  • In many instances it can support part consolidation and geometries that are impractical and/or impossible to injection mold
  • Allows for the production of end-use parts at unmatched speed: up to 100 times faster than other additive manufacturing processes

The Technology

Carbon_Photo_AAt the heart of the Carbon Digital Manufacturing Platform is Carbon Digital Light Synthesis™ technology, a software-controlled process that uses light and oxygen to grow parts from a pool of resin.

Carbon’s innovation is enabled by breakthroughs in software, hardware and materials, including a unique oxygen-permeable window that enables parts to be built continuously, resulting in superior mechanical properties–a departure from layer-by-layer builds associated with other additive technologies.

While traditional 3D printed parts can be weak or brittle due to the layered printing, parts produced with Carbon’s technology are isotropic with the mechanical properties of an injection molded engineering grade resin.

Available Resins

Carbon offers a wide selection of high-performance resins that includes:

  • A medical Polyurethane that is biocompatible and can be sterilized
  • Polystyrene-like resins (Urethane Methacrylate family)
  • A soft-touch, biocompatible Silicone-Urethane
  • Tough, abrasion-resistant Polyurethanes similar to ABS
  • Cyanate-Ester resins with high strength and temperature resistance, similar to 15% GF Nylon
  • An Epoxy that is similar to 20% GF PBT
  • Elastomeric Polyurethanes similar to TPU
  • A tough, impact and abrasion resistant, flexible Polyurethane, similar to Polypropylene
  • Eight types of denture-related resins

For more information on these resins, click here.

Part Suitability

Industry wide, a diverse range of parts are currently being produced using the Carbon Digital Manufacturing Platform including medical device components, consumer product components, automotive components (Ford and Lamborghini), Riddell SpeedFlex Diamond Precision-Fit football helmet liners, Adidas Futurecraft 4D shoe midsoles and FDA-cleared dentures, to name just a few.

Using Carbon DLS™ technology, Makuta can produce working prototypes and limited-run production parts from roughly the size of a pea up to a size smaller than a shoebox, although many factors can affect suitability. Parts that are well suited include air and fluid manifolds, parts with fine features or textures, un-moldable geometries (such as complex lattices) and applications where part consolidation is desired.

For parts about the size of two fingers (1 x 2 x 3 inches), 10 to 20 parts could be produced per build cycle making the part especially well-suited for limited run-production.

For prototyping of micro-sized parts, including very thin walls and exceptionally tight tolerances, click here for Makuta’s advanced micro-sized parts solutions.

Makuta looks forward to the opportunity to discuss your small or complex part prototype and production requirements. Call (317) 642-0001 or email us at info@makuta.com.