BCN3D Unveils Viscous Lithography Manufacturing (VLM): Revolutionizing Industrial Resin 3D Printing

For a decade, BCN3D has been a notable player in the FDM 3D printer market, consistently delivering innovative solutions for various industries. Today, the Barcelona-based manufacturer marks a significant turning point in its journey with the introduction of a truly transformative technology, poised to redefine possibilities in additive manufacturing. After three years of intensive research and development, BCN3D proudly unveils its “Viscous Lithography Manufacturing” (VLM) technology. As its name profoundly suggests, VLM is a cutting-edge 3D printing process specifically designed for highly viscous resins, fundamentally rooted in the principles of stereolithography. While it shares conceptual similarities with established resin-based processes like mSLA and DLP in its use of light to cure liquid resin, BCN3D’s VLM technology is engineered to overcome many of their inherent limitations, offering a distinct and superior approach to industrial additive manufacturing. This article delves into the intricacies of VLM, exploring its operational mechanics, the profound advantages it brings to various industries, and its potential to redefine the landscape of industrial resin 3D printing.

The Genesis of Viscous Lithography Manufacturing (VLM) Technology

The highly anticipated VLM technology was officially revealed by BCN3D during a comprehensive press conference held on March 2nd. At the core of VLM’s innovation lies its ability to process exceptionally viscous resins, a capability that sets it apart from conventional resin 3D printing methods. Traditional resin printers often struggle with high-viscosity materials due to challenges in flow and leveling, limiting the types of resins that can be used and thus the mechanical properties of the final parts. VLM, however, embraces this challenge. The system operates by temporarily fixing the material in suspension directly under a specialized film. This film, supplied in a continuous roll, ingeniously transports the resin from its dedicated cartridge to the precise location where the part is being printed, creating a thin, controlled layer of viscous material. Once this resin layer is in position, a meticulously controlled UV-A light source, precisely masked by a monochrome LCD screen, selectively cures and solidifies the resin layer by layer, building the object with remarkable accuracy. A critical differentiator of VLM is its sophisticated material management. After each layer is successfully produced, the film intelligently moves the uncured, non-polymerized resin into an integrated filtration system. This innovative step ensures that any excess resin is cleaned and made ready for immediate reuse, significantly reducing material waste and improving overall efficiency, especially in single-material printing operations where material costs can be substantial.

Operational Advantages: Eliminating the Resin Vat and Enabling Multi-Material Capabilities

One of the most radical departures of the VLM system from traditional resin 3D printers is the complete absence of a resin vat. Instead of submerging parts in a large pool of resin, which is common in mSLA or DLP printers, VLM printers produce objects directly on a printing plate. This fundamental design choice offers several significant advantages that enhance user experience, reduce operational costs, and improve environmental impact. Firstly, it eliminates the need for large volumes of resin to be exposed to air and light for extended periods, reducing potential degradation, minimizing evaporation, and improving material longevity. Secondly, it drastically simplifies the cleaning and maintenance processes, as operators no longer need to handle or dispose of large quantities of liquid resin from a vat, making the workflow cleaner and safer. Furthermore, printing directly on a plate ensures that parts do not soak in a bath of uncured resin, often leading to cleaner prints that require less post-processing effort for surface cleaning, thereby saving time and resources. This innovative approach also inherently reduces the risk of resin contamination from dust or ambient light, a common issue in open vat-based systems.

Perhaps the most groundbreaking feature enabled by the vat-less design and the rolling film mechanism is the unprecedented ability to print different materials simultaneously within a single build. This capability was previously considered impossible with other resin technologies, which are typically confined to using a single type of resin per print job, forcing users to choose between material properties or conduct multiple print runs for multi-component assemblies. VLM achieves this through its independent resin cartridges and the precise, controlled movement of the film, which effectively prevents cross-contamination between materials. By isolating different resins within their respective cartridges and delivering them precisely layer by layer via the film, BCN3D has unlocked a vast array of new applications. Imagine creating functional parts with varying mechanical properties within a single print, such as a tool with a rigid handle and a flexible gripping surface, or a complex medical device integrating both biocompatible and structural elements. This multi-material functionality opens doors for the development of highly complex, functional prototypes and end-use parts that were once unachievable with existing additive manufacturing processes, pushing the boundaries of design and engineering. While multi-material printing does lead to a slightly increased resin waste during the transitions between different materials to avoid any potential cross-contamination, the overall benefits and expanded design possibilities far outweigh this minor drawback, especially for high-value industrial applications where performance and complexity are paramount.

The “Why” Behind VLM: Unlocking High-Performance Materials and Enhanced Properties

The fundamental impetus behind the development of VLM technology stems from the desire to leverage the full potential of advanced materials that are often too challenging for conventional resin 3D printing. This technology uniquely allows for the successful printing of resins up to 50% more viscous than those manageable by current stereolithography processes. This expanded viscosity range is not merely a technical achievement; it is a gateway to a new generation of high-performance materials. Viscous resins typically allow for higher filler content, meaning they can incorporate more particles, fibers, or other reinforcing agents that significantly enhance the material’s properties. BCN3D has strategically partnered with Arkema, a global leader in specialty materials, to develop and offer a robust range of advanced resins specifically optimized for VLM. This collaboration ensures that users will have access to a diverse portfolio of materials with superior mechanical, thermal, and chemical properties, addressing the stringent demands of various industrial applications.

The ability to utilize highly viscous resins also means that manufacturers can incorporate a higher proportion of additives into their formulations. These additives, which can range from reinforcing fibers and particles to specialized functional agents, are crucial for tailoring the mechanical and physical properties of printed parts precisely to application requirements. By enriching resins with a greater density of these performance-enhancing additives, VLM enables the production of parts with significantly improved characteristics. BCN3D confidently states that by using these specially formulated viscous resins, VLM can produce parts that are up to three times more resistant to impact and exhibit a remarkable 200% increase in tensile strength compared to parts printed with conventional resin technologies. These enhancements translate directly into more durable, reliable, and functional end-use components, opening up critical applications in industries such as automotive, aerospace, defense, and medical where material performance and resilience are paramount for safety and longevity.

Furthermore, BCN3D highlights that the high viscosity handled by VLM greatly facilitates the production of intricate biomaterials and the creation of highly isotropic parts. For biomaterials, the precision, material flexibility, and ability to handle specialized viscous formulations offered by VLM can lead to advanced prosthetics, custom implants, and sophisticated tissue engineering scaffolds with tailored properties that mimic natural biological structures. The term “highly isotropic parts” refers to components that exhibit uniform mechanical properties in all directions, a critical factor for structural integrity and predictability in demanding engineering applications. Achieving true isotropy in additive manufacturing has historically been challenging, with many processes creating parts that are stronger along one axis than another. However, VLM’s ability to precisely control the curing of viscous materials, combined with appropriate post-processing steps, makes this a more attainable goal, ensuring consistent and reliable performance regardless of load direction. These post-processing steps, such as washing, UV post-curing, and sometimes thermal treatments, are similar to those found in existing resin printing processes, ensuring a familiar workflow for users while consistently delivering superior part performance and quality.

Market Adoption, Strategic Vision, and the Future of BCN3D

While BCN3D is not yet offering VLM machines for general sale, the company has implemented an exclusive adoption program. This strategic initiative is designed to provide eligible industrial partners and key customers with early access to this revolutionary technology. By allowing selected companies to test and integrate VLM into their highly demanding workflows, BCN3D aims to gather invaluable feedback, refine the technology based on real-world applications and diverse industrial scenarios, and foster a strong ecosystem around VLM, including material development and specific application methodologies. This strategic approach ensures that when VLM machines officially hit the broader market, they will be robust, proven, and perfectly aligned with the nuanced and demanding needs of industrial manufacturing environments.

BCN3D assures that this innovative process is slated to enter the broader market within the next few years, with machines anticipated to be priced at less than €50,000. This highly competitive price point positions VLM as an accessible yet incredibly high-performance solution for a wide range of industrial manufacturers looking to invest in advanced additive manufacturing capabilities without the prohibitive costs often associated with cutting-edge technologies. Such pricing democratizes access to technologies that deliver exceptional material properties and multi-material functionality, potentially accelerating the adoption of industrial resin 3D printing across various sectors, from specialized prototyping to end-part production.

This new announcement also signifies a pivotal shift in BCN3D’s corporate strategy. Historically, BCN3D has been a staunch advocate for open-source hardware and software, a philosophy that has greatly benefited the FDM community by fostering innovation and collaboration. However, with the advent of VLM, the company is making a significant strategic decision to patent this novel technology. This move is a clear indication of the groundbreaking nature of VLM and BCN3D’s commitment to protecting its intellectual property in this new frontier. Patenting VLM allows BCN3D to secure its competitive advantage, foster further investment in crucial research and development, and maintain its leadership in this emerging segment of additive manufacturing. Crucially, during the press conference, BCN3D unequivocally reassured its community that its existing FDM machines and related processes would continue to operate under an open-source model. This dual strategy demonstrates BCN3D’s ability to innovate fiercely and protect its cutting-edge advancements while remaining true to its roots and community in established additive manufacturing areas.

Conclusion: A New Horizon for Additive Manufacturing

BCN3D’s Viscous Lithography Manufacturing (VLM) technology represents far more than just another iteration in resin 3D printing; it is a paradigm shift. By enabling the processing of highly viscous, high-performance materials and unlocking the unprecedented capability for true multi-material additive manufacturing within a single print job, VLM addresses critical limitations of existing technologies. Its innovative vat-less design streamlines material handling, significantly reduces waste in many scenarios, and enhances part strength, durability, and isotropy, which are crucial for industrial applications. This innovation is set to empower industries with the tools to create more durable, functional, and complex components than ever before, propelling additive manufacturing into new applications and markets previously thought unattainable. As VLM progresses from its exclusive adoption program to wider market availability, it promises to be a game-changer, solidifying BCN3D’s position at the forefront of advanced industrial 3D printing solutions and driving forward the capabilities of digital manufacturing worldwide.

What applications do you foresee benefiting most from the unique capabilities of VLM technology, especially its multi-material printing and high-viscosity material processing? We encourage you to share your insights and predictions in a comment below or join the discussion on our LinkedIn, Facebook, and Twitter pages! Don’t miss out on the latest advancements and breaking news in 3D printing; sign up for our free weekly Newsletter here, delivered straight to your inbox. You can also explore all our in-depth videos and tutorials on our YouTube channel.