DLP – Digital Light Processing
DLP 3D printing for demanding applications
High resolution, tight tolerances and a broad material portfolio. Find out when DLP is the right choice for your R&D or production parts — and how to get the most out of the process.
Why our DLP knowledge runs deeper..
Tenco DDM was the technology partner in Europe of Henkel to apply Digital Light Processing for industrial series production.
The German multinational engaged Tenco to both support customers and develop applications through to series production based on their Loctite materials. Customer enquiries at the time came directly to Henkel or were referred to Tenco. Through this close collaboration, Tenco built up a lead in DLP with Loctite’s high-performance materials.
Over time, Tenco has increasingly specialised in other special materials for, amongst others, DLP, SLA % FDM, and now applies also materials from suppliers such as Igus, ForwardAM (formerly BASF), 3D Resyns, Raplas, and EnvisionTec.
Technology
DLP (Digital Light Processing) cures liquid photopolymer resin with a UV projector — one full layer at a time. This results in exceptionally smooth surfaces, sharp fine details and dimensional accuracy.
DLP relies on digital micromirror devices (DMDs), which contain hundreds of thousands (or millions) of tiny mirrors, each representing one pixel of the projected image. The DMD reflects light from a projector or UV light source through a lens, projecting a precise image of the desired cross-section of the 3D model onto a vat of liquid photopolymer resin.
Comparison with SLA – Stereo Lithography
DLP is often compared with stereolithography (SLA), another photopolymer-based technology. While SLA uses a laser to trace the shape of each layer, DLP projects the entire layer at once. This difference makes DLP faster for smaller parts, as it cures complete layers simultaneously, while SLA can offer higher resolutions for larger objects and allows to build large objects without internal stress.
Main Features DLP
High resolution and detail
Layer thicknesses of 25 to 100 µm. Ideal for fine geometries, thin walls, and complex surface details that are critical for form/fit testing.
Speed
Typically faster than SLA for many parts since entire layers are cured at once.
Broad material portfolio
From standard and tough resins to flexible, castable and dental-grade. The right material for every R&D requirement.
Tight tolerances
±0.1–0.2 mm dimensional accuracy in XY. Well suited to fit checks, functional prototypes and master patterns for moulding applications.
Smooth Surfaces
Produces smooth surfaces, though the pixel-based curing can sometimes result in visible voxels (tiny, 3D pixels).
Known limitations
DLP parts can be relatively brittle, UV-sensitive over time and require support structures and post-curing. Not suited for load-bearing end-use parts.
Standard resin
High resolution, smooth surface finish, limited impact resistance. For visual prototypes and form/fit validation.
Flexible / rubber-like
Shore A 40–80. Gaskets, seals, soft grips and vibration-damping components.
High-temperature resin
HDT up to + 220°C. For moulds, jigs and parts used in warm environments or autoclave applications.
Tough / ABS-like resin
Improved impact resistance and ductility. Suited to functional assembly checks and snap-fit components.
Castable resin
Ash-free burnout. Master patterns for lost-wax casting in metal — jewellery, dental, precision casting
Dental / medical-grade
Bio-compatible (ISO 10993). Surgical guides, dental models, splints. Strict post-processing protocol required.
DLP in practice – customers cases
Carburetor parts for competition go-kart team replacing metal parts
A carburetor was adapted to a different engine geometry. DLP was chosen for its dimensional accuracy, liquid and gas tightness, shape stability and chemical resistance to petrol and oil. After a successful tests, the first batch of 45 sets were produced and deliverd.
Loop Earplugs
Beyond prototyping and testing, additive manufacturing was the way forward for serial production to reduced time to market. Over 2000 shells have been produced and post-processed to make a successful launch possible.
Succesfull launch of pre-production serie of 200 bio-compatible housing sets
Tenco supported from development to delivery of the first pre-production batch, including all post-prodction services such as coatings and markings.
Bioracer Motion – Housings and 22 microns accurate lenses for IR-senors with DLP
DLP technology was chosen for the development and final production of IR-sensors for analyzing the posture and movements of cyclists.
