pr Photolithography Prototyping|crossEffect, Inc.

Photolithography Prototyping

New technology for prototyping thermoplastic resin without metal molds.
Quickly and cheaply create actual models with the same properties as molded items.

Photolithography Prototyping

Possible to prototype with the final output material! Photolithography results in prototypes that cannot be realizes by 3D printers.

Photolithography is a technology for molding three-dimensional models. Fine particles are formed into a silicon mold is then vacuum compressed and irradiated with light from the outside. This creates a mold of a solid three-dimensional model that has been melted together. It is possible to manufacture the molded model swiftly using the final out material, and at low cost. Photolithography is optimal for manufacturing on-demand, small lot products, small quantities of various products, and for design and manufacturing that has a short turnaround.

  • 2-hour support
  • Rapid Prototyping
  • Vacuum Casting
  • Rapid design
  • Surface Processing
  • Medical Prototying
  • 3D Data Creation
  • CT Scan
  • Transparent Plastic Service
  • Express Rapid Prototying
  • Small Economy Service

*Grey icons may be supported depending on conditions.

  • Mold of actual model made from thermoplastic resin utilizing silicon rubber. Metal molding not required.
  • Swift and low cost manufacturing of a model that has the same properties as an injection molded item.
  • Possible to mold with the desired grade of thermoplastic resin.

Principles of Photolithography

Silicon rubber is a processing material presently used in vacuum casting, but it has low rigidity and cannot be used for injection molding. Photolithography can create rubber-based photo thermoplastic resin models by combining three new processing methods: fine particle filling, selective heating, and vacuum clamping.

Principles of Photolithography

Steps of Photolithography

1. Vacuum Casting Process

  • Creation of photolithography master model or provision of master model

    Creation of photolithography master model
    or provision of master model

  • Silicon rubber is cast.

    Silicon rubber is cast.

  • Master model is removed after hardening.

    Master model is removed
    after hardening.

2. Plastic Microfilming Process

  • 2. Plastic Microfilming Process
  • 1. Vacuum Casting Process

  • 2. Plastic Microfilming Process

  • Creation of photolithography master model or provision of master model

    Creation of photolithography master model
    or provision of master model

  • Silicon rubber is cast.

    Silicon rubber is cast.

  • Master model is removed after hardening.

    Master model is removed
    after hardening.

  • Plastic Microfilming Process

3. Microwave Formation

Pre-filling of micropellets (fine particle filling)
Pre-filling of
micropellets
(fine particle filling)
Compression of molten resin (selective heating / vacuum clamping)
Compression of molten resin
(selective heating / vacuum clamping)
Cooling - demolding / finishing(burr removal, etc.)
Cooling - demolding / finishing
(burr removal, etc.)

Differences with Conventional Technologies

Due to the nature of conventional 3D printers and rapid prototyping machines, the type of resin material that can be used is limited. There are large restrictions in applicability, as molded pieces that use regular thermoplastic resin cannot be created. In order to produce prototypes that have been melted together as a whole with mass production material, the thermoplastic resin molded must be made with metal molding. This results in a burdensome situation when it comes to development time and cost. In addition, 3D printers have difficulty with layering, so it is difficult to produce a prototype that can withstand practical function evaluations.

Photolithography’s Position: RP Field (Prototype Field) + RM Field (Small Number of Several Product Types)

Photolithography’s Position
Click here for enlarged view

Micropellet Base Stock (As of 9/2016)

Type Manufacturer Grade Color
ABS Techno Polymer 330 Black
Techno Polymer 330 Natural
Techno Polymer 430 Natural
PC/ABS Teijin Multilon TN-7500 Black
PS PSJ SGP10 Transparent
PP Prime Polymer J704UG Black
Japan Polychem Novatec BC6D Black
Japan Polychem Novatec BC6D Natural
Japan Polychem Novatec BC05B Natural
Japan Polychem Novatec EC9 Black
HDPE Japan Polychem Novatec HD HJ580N Natural
LLPE Japan Polychem Novatec LL UJ580 Natural
LDPE Japan Polychem Novatec LD LJ803 Natural
PMMA Mitsubishi Rayon Acrypet VH001 Transparent
Asahi Kasei Delpet 70NH Transparent
POM Polyplastics Duracon M90-44 Natural
Polyplastics Duracon M90-44 Black
PC Teijin Panlite AD-5503 Transparent
Mitsubishi Engineering-Plastics Corporation Iupilon S3000 Transparent
Teijin Panlite L1225Y Transparent
PA Asahi Kasei Leona 1300SJ1 Black
ABS-GF Techno Polymer 130GF20 Black
PG/GF Mitsubishi Engineering-Plastics Corporation Iupilon GMS2020DR BK Black
Type
Manufacturer Grade Color
ABS
Techno Polymer 330 Black
Techno Polymer 330 Natural
Techno Polymer 430 Natural
PC/ABS
Teijin Multilon TN-7500 Black
PS
PSJ SGP10 Transparent
PP
Prime Polymer J704UG Black
Japan Polychem Novatec BC6D Black
Japan Polychem Novatec BC6D Natural
Japan Polychem Novatec BC05B Natural
Japan Polychem Novatec EC9 Black
HDPE
Japan Polychem Novatec HD HJ580N Natural
LLPE
Japan Polychem Novatec LL UJ580 Natural
LDPE
Japan Polychem Novatec LD LJ803 Natural
PMMA
Mitsubishi Rayon Acrypet VH001 Transparent
Asahi Kasei Delpet 70NH Transparent
POM
Polyplastics Duracon M90-44 Natural
Polyplastics Duracon M90-44 Black
PC
Teijin Panlite AD-5503 Transparent
Mitsubishi Engineering-Plastics Corporation Iupilon S3000 Transparent
Teijin Panlite L1225Y Transparent
PA
Asahi Kasei Leona 1300SJ1 Black
ABS-GF
Techno Polymer 130GF20 Black
PG/GF
Mitsubishi Engineering-Plastics Corporation Iupilon GMS2020DR BK Black

Unsupported Resins

Materials with a high processing temperature are not supported due to issues with mold durability.
Super engineering plastics cannot be molding. Photolithography supports resins that melt at 300℃ or lower.

Estimates

Photolithography Reference Prices

Prototype Examples Using Photolithography

Prototype Examples Using Photolithography
Prototype Examples Using Photolithography
Prototype Examples Using Photolithography