SLA 3D printed art lighting components for a UK client

Project background

A UK-based customer in the art lighting industry had a complex requirement for a set of 62 custom-made art lighting fixtures, each with unique material specifications and surface treatments for each component. The 3d printed art lighting components project involved a variety of surface treatments, including spray painting, chrome plating, gold-plating, silver-plating, fine polishing, and high transparency.

The complexity of the project was further compounded by the need for rigorous assembly testing, and the requirement for high surface finish quality. The customer’s specifications were precise, and they required the utmost attention to detail and accuracy in the manufacturing process. To meet the customer’s requirements, M2 Prototype team had to carefully select materials, surface treatments, and assembly processes for each component to ensure the final product met the customer’s high standards. We also had to ensure that each fixture was unique and met the specific requirements of the customer, resulting in a truly bespoke product.

The project required a high level of expertise and attention to detail, which the manufacturer was able to provide. The final product was not only functional but also aesthetically pleasing, meeting the customer’s expectations and demonstrating the manufacturer’s ability to deliver complex and custom-designed products.

Technical Challenges

The project of manufacturing 62 custom-made art lighting fixtures posed several technical challenges, including:

Producing numerous parts with different requirements and finishes while maintaining consistency and quality
Meeting the customer’s high transparency, smoothness, and attention to detail requirements
Completing the project within a tight timeframe of 15 days

The complexity and intricacy of the components added to the challenges faced in this project. Each component had different material requirements and surface treatments, which included spray painting, chrome plating, gold-plating, silver-plating, fine polishing, and high transparency. The intricate shapes and details of the components made it difficult to achieve the desired surface finish.

The customer’s requirements for high transparency, smoothness, and attention to detail added to the technical challenges. The components required a high level of clarity and smoothness to ensure that the light transmitted through them without any obstruction. Moreover, the intricate shapes and details of the components required high accuracy and precision in manufacturing to meet the customer’s specifications.

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Solutions

SLA (Stereo Lithography Apparatus) 3D printing technology was selected by M2 team as an ideal solution to overcome the technical challenges faced in the project of manufacturing 3d printed art lighting components. The use of SLA 3D printing technology offered several benefits, which are as follows:

High accuracy, speed, and flexibility in producing complex shapes and intricate details
Ability to produce multiple parts with different requirements and finishes while maintaining consistency and quality
Wide range of material options, including transparent materials, which met the customer’s specifications
Suitable for small batch production, making it perfect for this project

The specific type of SLA resin material used in the project was a transparent photosensitive resin. This material provided exceptional clarity, impact resistance, and durability, making it an ideal choice for meeting the customer’s high transparency requirements. The resin was cured layer by layer using an SLA 800 3D printer, which allowed for the production of intricate shapes and details with high accuracy and precision.

Post-processing techniques were used to achieve the desired surface finish of the components. The resin components were first removed from the build platform and cleaned with isopropyl alcohol to remove any uncured resin. The components were then post-processed using sanding and polishing techniques to achieve a high-quality surface finish that met the customer’s requirements.

Production Process

The production process for manufacturing 62 custom-made art lighting fixtures using SLA 3D printing technology involved several steps, including:

Customer Collaboration: The project started with a collaboration between the UK-based art lighting customer and the manufacturing company. The customer provided the specifications and requirements for the components, including material requirements, surface treatments, and high transparency requirements.
Reviewing and Clarifying Specifications: The manufacturing company reviewed and clarified the specifications and requirements with the customer to ensure that all requirements were clear and concise. This step was crucial in ensuring that the final product met the customer’s expectations.
Slicing Software Preparation: The components’ 3D models were imported into the slicing software, which prepared the files for printing. The software sliced the 3D models into thin layers and generated the G-code instructions required for the SLA 800 3D printers.
SLA Printing: The SLA 800 3D printers were used to print the components. The printers used a laser to cure the transparent photosensitive resin layer by layer, resulting in a highly accurate and precise print with intricate shapes and details.
Post-Processing: The printed components were removed from the build platform and cleaned with isopropyl alcohol to remove any uncured resin. The components then underwent post-processing, which included sanding and polishing techniques to achieve a high-quality surface finish.
Assembly Testing: The components were manually assembled into the final products, and rigorous testing was conducted to ensure correct functionality and safety standards.
Packaging and Shipping: The final products were carefully packaged using appropriate materials and shipped to the customer, ensuring the safety of the components during transport.

The importance of reviewing and clarifying specifications and requirements with the customer cannot be overstated. This step ensures that all requirements are clear and concise, reducing the risk of errors and ensuring the final product meets the customer’s expectations.

The slicing software preparation process played a crucial role in achieving the desired surface finish and accuracy of the components. The software sliced the 3D models into thin layers and generated the G-code instructions required for the SLA 800 3D printers, ensuring the correct printing parameters were used.

The use of SLA printing technology was key to producing the components with high accuracy, speed, and flexibility. SLA printing technology is ideal for producing complex shapes and intricate details, offering a high degree of accuracy and precision.

The SLA 800 3D printers were used to print the components, with each printer capable of printing multiple components simultaneously. This allowed for the efficient production of multiple components while maintaining high accuracy and precision.

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Surface Finishing

The 62 custom-made 3d printed art lighting components required specific surface treatment processes to achieve the desired surface finish. The following are the specific surface treatment processes used for each component:

Polishing: The polished components underwent a polishing process to achieve a highly reflective and smooth surface finish. This process was crucial in meeting the customer’s requirements for high surface finish quality.
Sanding: The sanding process was used to remove any imperfections or rough edges from the components. This process ensured that the components were smooth and free of any defects, meeting the customer’s requirements for high surface finish quality.
Spray Painting: The spray painting process was used to apply a thin layer of paint to the components’ surface. The paint layer was used to enhance the aesthetic appeal of the components and provide a protective coating, ensuring the longevity of the components.
Electroplating: The electroplating process was used to coat some of the components with a thin layer of metal. This process was crucial in achieving the desired color and surface finish and protecting the components from wear and tear.

Assembly Test

The final products of the 62 custom 3d printed art lighting components were manually assembled to ensure correct functionality and safety standards. The following describes the manual assembly process M2 team used for the final products:

Preparation: The components were cleaned and prepared for assembly. This process ensured that the components were free of dust and debris, which could affect the assembly process.
Assembly: The components were manually assembled according to the customer’s specifications. The assembly process required a high level of accuracy and attention to detail to ensure that the final products met the customer’s requirements.
Testing: Rigorous testing was conducted to ensure correct functionality and safety standards. The importance of rigorous testing cannot be overstated. Testing ensured that the final products were safe and functional and met all customer requirements. Any defects or issues were identified and addressed during the testing phase, preventing any potential safety hazards or performance issues. The testing process involved a combination of visual inspection and testing. Visual inspection was used to identify any defects or issues with the components, while testing was used to ensure that the final products met the customer’s requirements for functionality and safety standards.

Packaging and Shipping

Careful packaging and shipping are essential for delicate parts such as the custom-made art lighting fixtures to ensure that they arrive at their destination safely and in good condition. The following explains the importance of careful packaging and shipping for delicate parts:

Protection: Careful packaging and shipping ensure that the components are protected from any damage during transport. Delicate components can be easily damaged, and the packaging and shipping process must take into consideration any potential risks to ensure that the components arrive in good condition.
Security: Careful packaging and shipping ensure that the components are secure during transport. The packaging must be designed to prevent any movement or shifting of the components during transit, which could cause damage.
Presentation: Careful packaging and shipping ensure that the components arrive at their destination in good condition, improving the customer’s perception of the manufacturing company’s quality and attention to detail.

The specific packaging materials and techniques used to ensure the safety of the components during transport included:

Bubble Wrap: Bubble wrap was used to wrap each component to provide cushioning and protection against any potential impacts during transport.
Foam Inserts: Foam inserts were used to secure each component in place and prevent any movement during transit.
Cardboard Boxes: Cardboard boxes were used to contain the components and provide additional protection during transport.
Fragile Labels: Fragile labels were used to indicate that the components were delicate and require careful handling.

Customer Feedback

The customer’s feedback on the final product was highly positive. The product met all their expectations in terms of design, functionality, and aesthetics. The custom-made components were personalized to meet the customer’s specifications and requirements, resulting in a highly satisfactory design. Rigorous testing ensured that the components were safe and functional, meeting the customer’s expectations in terms of functionality. The high surface finish quality of the components met the customer’s requirements for aesthetic appeal, enhancing the overall appearance of the final products. The customer expressed their satisfaction with our level of communication and collaboration throughout the project, highlighting our attention to detail and quality. Overall, the customer’s positive feedback was a testament to our commitment to providing high-quality 3d printing service for artworks that meet their customers’ specific requirements.