Published on Tue Aug 08 2023 05:25:34 GMT+0000 (Coordinated Universal Time) by Alex

Diving Deep: A Comprehensive Look at the EnvisionTEC Perfactory Apollo 3D Printer

The EnvisionTEC (now ETEC, a Desktop Metal company) Perfactory Apollo is a high-resolution, industrial-grade 3D printer designed for manufacturing functional parts with exceptional surface finish and accuracy. It’s a workhorse in various industries, from medical and dental to manufacturing and jewelry. Let’s dissect what makes this printer a compelling choice for professionals.

Unveiling the Specifications: Inside the Apollo

Before diving into applications, let’s establish the core specs that define the Perfactory Apollo:

• Technology: Digital Light Processing (DLP)
• Light Source: High-performance projector with LED
• Build Volume: Varies depending on the selected build style and material. Typical range is around 100mm x 75mm x 100mm to 192mm x 120mm x 180mm
• XY Resolution: Down to 10 µm (micron) depending on material and configuration
• Layer Thickness (Z Resolution): Down to 25 µm (micron), adjustable for speed and resolution trade-offs
• Materials: Broad range of proprietary and open materials compatible with DLP technology, including resins for engineering plastics, elastomers, castable waxes, and biocompatible materials. Specific material support is highly dependent on the exact Apollo model variant.
• Connectivity: Ethernet, USB
• Software: Perfactory RP Software Suite
• Power Requirements: Varies based on specific Apollo model.
• Physical Dimensions: Relatively compact for an industrial printer. Varies depending on model. Expect it to require a dedicated workspace.
• Weight: Varies depending on model, typically around 80-120 kg.

Key Takeaways from the Specs:

• High Resolution: The Apollo’s defining feature is its exceptionally high resolution, making it ideal for intricate designs and fine details.
• Material Versatility: Support for diverse materials expands the applications beyond prototypes, allowing for functional parts in various industries.
• Software Integration: The included software suite is crucial for optimized print preparation and control.
• Industrial Design: The Apollo is built for demanding environments and sustained operation.

Mastering the Perfactory Apollo: Usage Tips and Best Practices

Operating the Apollo effectively requires understanding its nuances and adopting best practices.

1. Material Selection is Paramount:

• Understand Material Properties: Before any print, deeply understand the chosen material’s characteristics – tensile strength, elongation, HDT (Heat Deflection Temperature), and any post-processing requirements.
• Material Compatibility: Strictly adhere to the manufacturer’s compatibility guidelines for your specific Apollo model. Mismatched materials can damage the printer.
• Storage: Store materials in a dark, temperature-controlled environment, as specified by the manufacturer. Degradation from UV light or extreme temperatures can significantly impact print quality.
• Expiration Dates: Pay close attention to material expiration dates. Using expired materials can lead to print failures or compromised part properties.

2. Print Preparation in Perfactory RP:

• Orientation Matters: Part orientation profoundly impacts print time, support structure requirements, and surface finish. Experiment with different orientations to minimize supports and optimize surface quality. Consider using specialized support generation tools.
• Support Structure Design: Carefully design support structures for minimal material usage while ensuring adequate support for overhanging features. Remove supports carefully after printing.
• Slicing Parameters: Experiment with layer thickness and exposure settings. Thinner layers yield higher resolution but increase print time. Optimize exposure times for your chosen material to ensure proper curing.
• Hollowing and Drainage: For larger parts, consider hollowing them to reduce material consumption and print time. Implement drainage holes in the design to prevent resin from trapping inside the hollowed part during printing.

3. Machine Maintenance:

• Regular Cleaning: Clean the build platform and projector regularly to prevent resin buildup and ensure consistent print quality. Use the recommended cleaning solutions and procedures.
• VAT Film Care: The VAT film (the transparent bottom of the resin tank) is a critical component. Inspect it regularly for scratches or damage and replace it as needed. Mishandling the VAT film can cause print failures.
• Calibration: Regularly calibrate the printer to ensure proper alignment and accuracy. Consult the manufacturer’s guidelines for the recommended calibration schedule.
• Preventive Maintenance: Follow the manufacturer’s recommended preventive maintenance schedule, including lubrication of moving parts and inspection of critical components.

4. Post-Processing:

• Cleaning: Thoroughly clean the printed parts with isopropyl alcohol (IPA) or other recommended solvents to remove uncured resin. Use multiple cleaning stages for best results.
• Post-Curing: Post-cure the parts in a UV curing chamber to fully crosslink the resin and achieve optimal mechanical properties. The post-curing time and intensity depend on the material.
• Support Removal: Carefully remove support structures using appropriate tools. Take care to avoid damaging the printed part.
• Finishing: Depending on the application, you may need to perform additional finishing steps, such as sanding, polishing, or painting.

5. Troubleshooting:

• Document Everything: Keep a detailed log of print settings, material batches, and any issues encountered. This will help you identify patterns and troubleshoot problems more effectively.
• Start Simple: When troubleshooting, start with the simplest possible test prints. Isolate the problem by varying one parameter at a time.
• Consult the Manual: Refer to the printer’s manual and the material manufacturer’s guidelines for troubleshooting advice.
• Contact Support: If you’re unable to resolve the issue yourself, contact the manufacturer’s support team for assistance.

The Verdict: Is the Perfactory Apollo Right For You?

The EnvisionTEC Perfactory Apollo is a powerful tool for producing high-resolution, functional parts. Its material versatility, robust build quality, and advanced software suite make it a valuable asset for industries demanding precision and performance. However, it’s not a machine for beginners. Its complexity, material costs, and maintenance requirements necessitate a skilled operator and a dedicated workspace. If you need the highest level of detail and material options for demanding applications, the Apollo is a strong contender.

Overall Score

Here’s an evaluation of the EnvisionTEC Perfactory Apollo across key categories:

• Print Quality: 10/10
• Build Volume: 7/10 (Limited compared to some other technologies)
• Printing Speed: 7/10 (Can be slower than some other technologies, especially for large parts)
• Material Compatibility: 9/10 (Wide range of resins, but specific to DLP)
• Bed Adhesion & Leveling: 9/10 (Well-managed within the system)
• Reliability: 8/10 (Industrial-grade, but requires meticulous maintenance)
• Ease of Use: 6/10 (Requires significant expertise)
• Firmware and Software: 8/10 (Powerful Perfactory RP suite)
• Connectivity Options: 7/10 (Standard Ethernet and USB)
• Build Quality & Durability: 9/10 (Solid industrial design)
• Noise Level: 7/10 (Noticeable fan noise during operation)
• Maintenance Requirements: 5/10 (Requires regular cleaning, VAT film replacement, and calibration)
• Customer Support: 7/10 (Can vary depending on region and service contract)
• Upgradeability: 6/10 (Limited upgrade options after initial purchase)
• Price to Performance Ratio: 7/10 (High upfront cost, but justifiable for high-precision applications)

Average Score: 7.47/10

Written by Alex