Envisiontec Vanquish FC

EnvisionTEC is an established name in the rapid prototyping market. Since the launch of their initial product offering, the Perfactory, envisionTEC has seen a great deal of success and rapid adoption amongst the traditional stamping ground of rapid prototyping . Not only for design, engineering and manufacturing, envisionTEC has an infiltration into the jewelry , bio-medical modeling and dental sectors. Based on the Digital Light Processing (DLP) technology from Texas Instruments, the Perfactory differs from traditional photo-curable resin-based processes in that it's based on consumer-led technology typically used in movie theaters projectors or High definition televisions.

Essentially, where traditional SLA systems use expensive lasers to cure resin layer by layer, the Perfactory uses a series of projected bitmaps (photo images) to cure resin where needed. This is done repeatively until the movie of images is finished. This gives EnvisionTEC several advantages. The build speed achieved is particularly impressive, but perhaps more important advantage is the on-going and running costs of the machine. They are much lower than in a typical laser-based system (simply because there's no laser). Also, through the manipulation of light, envisionTEC maximizes the potential of the system by adjusting how the light is handled using lens.

As a result, the initial offering saw two variants of the same core machine, the Perfactory Standard and the Mini. The Perfactory Standard machine offers the user the ability to choose between different zoom levels and focal areas. This meant that the same machine could either build larger volume parts at slightly lower resolution (though we're still talking in the order of 0.93mm) or opt to build and focus on a slightly smaller area but achieve much higher resolutions (typically 0.32mm).
Another big advantage is that because the system is based on technology from the consumer realm, the organization could piggy back on the advances made by Texas instruments without incurring the research and development costs typically associated with such advanced technology. Essentially, as TI improves DLP, EnvisionTEC can then take those enhancements and apply them to their products (relatively easily). And this is exactly what's happened of late.

So let's take a look at what Envisiontec Vanquish FC can do. The Vanquish FC a large step up from the appliance-like nature of the Perfactory. The current unit is similar in terms of colour scheme (a rather fetching grey and orange combination) but looks much more similar to traditional SLA machines in terms of both size and portability (or lack thereof). Standing on a footprint of around a meter square and rising to about head height (depending on your stature obviously) the machine currently looks far more industrial than its predecessor. But what's really important is what it does and how it does it, so let's takes a look inside the box.
The Vanquish FC (the FC stands for Flash Cure by the way) is based on the same core technology and builds process found in the other Envisiontec products, but with one key difference. The Perfactory projects the photo image from below the build platform through a shallow vat of resin - which means the models are built upside down. Conversely, due to the size of models (and their associated weight) it can produce the Vanquish FC builds in a more traditional method. The photo image is projected from above, through a membrane onto a build platform which lowers into a much deeper vat of resin. It's this membrane that's key to the whole process. As the sections are built up, the model moves down into the vat to a predefined layer thickness. The transparent flexible membrane creates the same capillary action as you'd find in the Perfactory to add the next of 0.1mm layer of uncured resin across the surface of the model. Rollers then moves horizontal across the top of the membrane to ensure that the layer thickness is consistent across the whole part and that any bubbles are removed, and the membrane ensures that this does not come into contact with the resin

In both the standard and high-resolution modes, the build envelope varies in X and Y between 317.5mm x 254mm and 203mm x 162.5mm for maximum and minimum zoom respectively. The Z build height remains constant at 381mm. The real difference is the feature resolution and accuracy achievable. In Standard Resolution mode, maximum zoom gives you feature resolution (the smallest buildable feature) of between 0.246mm and 0.157mm depending on the zoom factor with accuracy between ±0.123mm and ±0.157mm. The High Resolution mode allows you to build down smallest feature resolutions between 0.144mm and 0.093mm with an accuracy varying between ±0.072mm and ±0.046mm. The other difference between the two modes is that build speed drops slightly from the maximum of 25mm per hour for the Standard Resolution mode to 19mm per hour when you're building in High Resolution mode.
Post processing of parts is minimal. The models come off the machine in a near fully cured state, and only really need post curing if you're looking to optimize mechanical strength (which might be advisable if you're looking for functional snap fits and the like). Other than that, models can be finished, painting, sanded, tapped etc as required without adverse effects on the part's structure.

Cost

The capital cost for the Vanquish FC is $170,000.00. In terms of on-going costs, a maintenance contract is available from EnvisionTEC which provides full coverage during a yearly period for approx. $15,900.00 per year. Consumables in the system are quite clear-cut. The projector unit is pretty much 'bullet proof' (again, a benefit of the consumer technology), but the projector bulb does need replacing every 1,000-1,500 hours (which equates to around 2-3 months of extensive use) and these costs $1,500.00 for a 2 pack to replace.

As you might imagine, resin is also a consumable and this is priced exactly the same as the Perfactory system, with each resin pack (which provides 1 Kilogram of material) costing around the $225.00. There are currently three material offerings across the entire EnvisionTEC range. The standard methacrylate is the dark orange material you often see associated with the machine. The other is a newer resin that's been requested by many of the customers in the jeweler market and dental market, which is directly castable or pressable. This should also see adoption by those within the design and engineering community for pattern making and investment purposes. A flesh colored material is also available for the biomedical device market. Other consumables are negligible, but the membrane that separates the build layer from the resin is replaceable and has a working life of around 1,000 hours (obviously depending on usage) and they cost $1200.00 to replace. Other than that, the system is free from the other types of maintenance costs traditionally associated with resin-based systems.

In conclusion

When we first looked at the Perfactory machine, it was pretty clear that the real advantage to the user came from the fact that it was based on consumer technology. This means that advances made in the mainstream electronics market by Texas Instruments could be readily and rapidly applied to the prototyping and direct manufacturing users of the EnvisionTEC machines. Both the commercialization of Vanquish FC machine and the delivery of the ERM module mean new customers and existing adopters are seeing this potential realized. For those looking to bring prototyping or direct manufacturing (as some customers are already doing with the Perfactory machines) technology in-house, there is now a range of EnvisionTEC products that give you a choice between opting for a small form factor machine or much larger build envelope for the heavier user. Whichever you plump for, the good news is that running costs are a great deal lower than many traditional, laser-based systems, but still retain the accuracy and build speed you need to ensure that the most is made of your investment.

In short, the Vanquish FC sees the Perfactory process reapplied to a much larger form factor and for those looking to maximize their productivity it is a much more appealing solution to an increasingly common problem. Ongoing costs associated with rapid prototyping technologies are a massive concern for many with their own facilities in house, but the good news is that EnvisionTEC has developed a machine that combines the large build volumes and increased productivity required by many within the industry with the low-maintenance and low running costs associated with their earlier products.