Carbon DLS: The Ultimate Guide to Digital Light Synthesis 3D Printing
- shiva ganesh
- Jul 30
- 4 min read
Table of Content
Introduction to Carbon DLS
What is Carbon DLS?
Carbon DLS (Digital Light Synthesis) is a proprietary additive manufacturing technology developed by Carbon, Inc. Unlike traditional 3D printing, Carbon DLS utilizes continuous liquid interface production (CLIP) combined with digital light projection (DLP) to rapidly produce high-resolution, isotropic, and end-use ready polymer parts. It delivers superior surface finish, mechanical properties, and speed, suitable for production-grade applications.
Carbon DLS bridges the gap between prototype and production, offering solutions for industries like automotive, medical, dental, sports equipment, and consumer goods.
A Brief History of Carbon DLS Technology
Carbon introduced DLS technology in 2015 with a bold vision: to turn 3D printing into a true manufacturing technology. Using a combination of light, oxygen, and programmable resins, Carbon DLS broke limitations seen in traditional layer-by-layer 3D printing methods.
How Carbon DLS Works
The Basic Workflow
Design in CAD software optimized for DLS principles.
Upload files to Carbon’s platform.
Print using DLS technology where light cures resin continuously through an oxygen-permeable window.
Post-process via washing, heat curing, and finishing.
Inspect parts for quality and dimensional accuracy.
Key Components of Carbon DLS Printers
Light Engine (DLP Projector)
Projects UV light patterns to shape parts layer-by-layer.
Oxygen-Permeable Membrane (CLIP Process)
Creates a “dead zone” preventing premature curing, allowing continuous printing.
Liquid Resin Vat
Holds the programmable photopolymer resin.
Build Platform
Supports the part as it’s pulled continuously from the resin.
Types of Carbon DLS Printers
M-Series (M1, M2, M3, etc.)
High-precision, scalable platforms for functional, end-use parts.
L-Series (L1)
Designed for large-scale production and larger build volumes.
Carbon DLS Printing Process
Continuous Liquid Interface Production (CLIP)
Utilizes oxygen-permeable windows and UV light to create a continuous, non-layered build process. This allows parts to be pulled from the liquid resin in a smooth, fast motion, eliminating mechanical stepping common in traditional 3D printing.
Thermal Post-Curing (Dual-Cure Process)
Printed parts undergo heat curing post-print to achieve final mechanical properties similar to injection-molded thermoplastics.
Materials Used in Carbon DLS
Programmable Liquid Resins
Rigid Polyurethane (RPU)
Durable, impact-resistant parts.
Elastomeric Polyurethane (EPU)
Rubber-like, flexible parts.
Silicone Urethane (SIL)
Soft-touch, skin-safe elastomers.
Epoxy (EPX)
High strength, engineering-grade parts.
Cyanate Ester (CE)
Heat-resistant and flame-retardant applications.
Flexible Polyurethane (FPU)
Flexible, semi-rigid applications.
Dental and Medical Resins
Biocompatible, certified for healthcare uses.
Applications of Carbon DLS
Medical & Dental
Custom aligners, surgical guides, dental models, orthotic devices.
Automotive
Functional interior components, ducting, brackets, housings.
Consumer Goods
Footwear midsoles, wearable devices, electronic housings.
Sports Equipment
Helmet padding, high-performance components.
Industrial Applications
Gaskets, seals, enclosures, complex lattice structures.
Advantages of Carbon DLS
Superior Surface Finish
Smooth surfaces comparable to injection-molded parts without heavy post-processing.
Isotropic Mechanical Properties
Strength and durability equal in all directions, unlike typical layer-based printing.
Fast and Continuous Production
DLS’s continuous printing process enables rapid production compared to SLA or FDM.
Production-Grade Materials
Wide range of thermoplastic-like materials for end-use parts.
Scalable for Mass Production
Used by global brands (Adidas, Ford) for large-scale manufacturing.
High Machine & Service Costs
DLS technology is typically accessed via subscription models and is more expensive than entry-level 3D printers.
Limited Accessibility
Primarily used by partner networks or enterprise clients, not hobbyists.
Post-Processing Required
Washing, support removal, and thermal curing are essential steps.
Carbon DLS vs. Other 3D Printing Technologies
Key Differences
Feature | Carbon DLS | SLA | FDM | MJF / SLS |
Process | Continuous liquid | Layered light-cure | Layered extrusion | Powder sintering |
Surface Finish | Injection-mold-like | Smooth | Layered texture | Powdery finish |
Mechanical | Isotropic | Brittle resins | Strong but anisotropic | Strong, isotropic |
Speed | Very fast | Moderate | Slow to moderate | Fast for batches |
Best Use | End-use parts | Prototypes, dental | Prototypes, tools | End-use batches |
When to Choose Carbon DLS
For production-quality parts with excellent mechanical properties.
When surface finish and durability matter.
For scalable, consistent production runs in demanding industries.
Future Trends in Carbon DLS
New Material Developments
Expanding materials for bioapplications, electronics, and aerospace.
Deeper Industry Integration
More automotive, medical, and consumer brands adopting DLS for direct manufacturing.
Automation & Smart Factories
Integration with Industry 4.0 environments for fully automated production lines.
Cost Considerations
Cost of Machines / Services
Subscription-based model: ₹25–₹50 lakhs annually depending on capacity.
Pay-per-use available through authorized service providers.
Cost of Operation
Premium resins: Higher cost than SLA or MJF materials.
Post-processing equipment (wash stations, ovens) adds to operational expenses.
Choosing the Right Carbon DLS Solution
Based on Material and Application
RPU, EPX: Durable parts requiring toughness.
EPU, SIL: Elastomeric applications like grips, seals.
CE: High-temp environments.
Based on Production Volume
Low-Mid Batch: M-Series.
High Volume / Large Parts: L-Series.
Tips for Getting Started with Carbon DLS
Training and Certifications
Carbon-certified user training.
Courses on design for DLS to leverage unique geometries and properties.
Recommended Tools and Resources
Software: Carbon platform, lattice structure optimizers.
Communities: Carbon partners, industry forums, LinkedIn groups.
Conclusion
Carbon DLS represents the future of 3D printing for production-quality polymer parts. Its speed, consistency, material range, and surface finish make it a go-to solution for industries requiring scale, precision, and durability far beyond prototyping.
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