Instructions for Use (IFU) & Printing Parameters for Asiga DLP printer

This document provides printer-specific guidance for using 3Dresyns® photopolymer resin systems on Asiga DLP platforms.

This page is a printer-specific supplement to the general Instructions for Use (IFU) & Printing Parameters for DLP & LCD printers and must be used together with it. It does not replace the general IFU and applies only to defined Asiga system configurations and workflows.

Key message: use the Asiga workflow as a qualified starting framework, not as a fixed universal recipe. Final settings must be selected through structured calibration under the real resin–printer–power conditions used on your system.

1) Scope, limitations and responsibilities

Scope of application

Applies to 3Dresyns® photopolymer resin systems processed by vat photopolymerization on selected Asiga DLP printers.
Applies to workflows where exposure power is selected or controlled within Asiga Composer profiles and validated by the user.

Limitations

This document provides reference workflows and a qualified calibration methodology, but it does not replace user-side validation.
3Dresyns does not control Asiga printer hardware, firmware updates or proprietary exposure algorithms. Users remain responsible for verifying compatibility and performance when integrating 3Dresyns materials with Asiga platforms.
Application-specific validation, regulatory compliance and final product qualification remain the responsibility of the user or legal manufacturer.

2) Material system and version control

3Dresyns® photopolymer resins are supplied as system-based materials that may exist in multiple formulation versions, viscosities, colours and functional configurations.

Before printing, verify that the selected resin version, lot number and associated documentation correspond to the intended printer technology and application.

Mixing versions, changing formulations or transferring parameters between materially different systems may invalidate expected performance.

Resin homogenization before printing

Resin homogeneity is part of process control. Materials should be mixed or homogenised appropriately before printing and re-homogenised as needed after storage, especially where pigments, fillers or functional additives may settle over time.

3) Record keeping (minimum)

For traceability and reproducibility, document at minimum:

resin name, version, viscosity, colour, additives and lot number,
Asiga printer model and wavelength configuration where applicable,
selected exposure power setting used in Asiga Composer and the profile or reference material used,
layer height, exposure time, burn-in exposure and number of initial layers,
orientation and support strategy,
washing chemistry, time and temperature,
drying method and time,
post-curing wavelength, power and time,
ambient conditions and any controlled thermal steps.

4) Reference printing parameters (starting points for Asiga)

The following are typical starting points for Asiga workflows. Lower or higher values may also be printable depending on resin formulation, selected exposure power and workflow optimisation. Final settings must be determined using the structured calibration logic below.

Z layer thickness: typically 0.050–0.100 mm
Normal exposure time: typically ~2–20 s for 50–100 µm layers, strongly dependent on resin behaviour and selected power
Burn-in exposure: typically ~75–90 s, often around 80 s, as an initial adhesion reference
Number of initial adhesion layers: typically 2–4, with 2 often sufficient in practical Asiga workflows

Interpretation rule: these are starting values, not universal print settings. Exposure times depend strongly on the selected exposure power, resin reactivity, target layer thickness and required green strength.

As a practical reference, 7 mW/cm² is commonly used in DentalMODEL-style starting profiles, but the correct settings must always be re-established for the actual resin and printer conditions.

5) Why exposure times are printer-specific on Asiga systems

Generic exposure times are only approximate and cannot guarantee reproducible results because:

real light power varies across the projected area,
light output changes with cumulative printer use and maintenance state,
different resins require different curing energies,
different Z layer thicknesses require different cured depths,
selected Composer power settings directly affect the energy delivered to the resin.

6) Why CRT is more flexible than fixed parameter presets

A major advantage of CRT-based calibration is that it allows the user to re-optimise printing settings for different Z layer thicknesses depending on whether the goal is higher speed, higher XY/Z resolution, improved dimensional control or a different balance between these variables.

With CRT, exposure selection is linked to measured curing behaviour under the selected Asiga power setting. This means the user can move from one target layer thickness to another and re-select the corresponding exposure window in a structured way.

By contrast, many workflows in the market are organised around fixed print settings tied to specific materials and specific layer heights. In those cases, changing the layer thickness often requires switching to another preset or manually creating and tuning a new print setting. CRT offers a broader engineering framework for adapting the same resin system to different Z strategies on the target Asiga printer.

Need faster printing? Increase layer thickness and recalibrate exposure.
Need finer Z resolution? Reduce layer thickness and recalibrate exposure.
Need different trade-offs for different parts? Use the same resin with different validated CRT-derived settings.

This is one of the main advantages of CRT compared with workflows based on fixed parameter presets tied to isolated Z-layer configurations.

7) Fast CRT logic for Asiga workflows

The Curing Rate Table (CRT) is the most practical method for selecting exposure times based on the real curing behaviour of the resin at the selected Asiga power setting.

For routine implementation, a fast CRT can often be started with only three points: 5 s, 10 s and 15 s.

Fast CRT recommendation for Asiga

Measure cured thickness at 5 s, 10 s and 15 s using the selected Asiga power setting.
Evaluate cured thickness and green strength of each cured drop.
Use these three points to identify the likely working interval for the resin and power configuration.
Then add 1–2 extra points only in the interval relevant to the target Z layer thickness and selected Asiga power.

In many practical cases, a burn-in exposure around 75–90 s provides a useful initial adhesion baseline, but this must still be validated for the specific resin–Asiga system. The main optimisation task then becomes the selection of the correct standard-layer exposure.

How to extend the fast CRT

If the practical exposure window is likely short, add points between 1 and 5 s or between 5 and 10 s.
If the resin is slower, more filled or the selected power setting is lower, add points between 15 and 20 s or above.

8) The scientific solution: Curing Rate Table (CRT) for Asiga workflows

CRT concept

The Curing Rate Table (CRT) is a resin–printer fingerprint. It establishes the relationship between exposure time and cured thickness under defined optical conditions and at the selected Asiga power setting.

Values shown in example tables are illustrative only and must not be used as universal settings. Users must generate their own CRT under their specific resin, Asiga model and exposure power conditions.

How to generate a CRT on Asiga (Spot Timer method)

Remove the build platform from the printer.
Place a small resin drop on a clean microscope glass slide.
Position the slide at the centre of the vat or tank.
Use the printer Spot Timer or equivalent exposure function and expose for a selected time.
Remove uncured resin and measure cured thickness using a digital caliper or micrometer.
Record cured thickness and qualitative green strength.
Repeat at increasing exposure times to build the CRT.

Reference CRT format (user-generated)

The table below shows a reference CRT structure for recording cured thickness versus exposure time. The exposure times and cured-thickness values shown are illustrative examples only and may vary depending on resin chemistry, selected Asiga power setting, optical configuration, temperature, wavelength and measurement conditions.

Important scientific note

The time points shown below are example CRT checkpoints, not universal settings. Different Asiga workflows may require shorter or longer exposure intervals depending on:

selected power setting in Composer,
real irradiance at the vat,
resin kinetics and reactivity,
pigments, fillers or additives,
printing temperature and viscosity,
target layer thickness and required green strength.

Exposure time (s)	Cured thickness (µm)	Evaluation of cure	Evaluation of adhesion on glass	Interpretation / practical use
5	Measured value	May range from uncured to weakly cured depending on the system	May range from none to poor adhesion depending on the system	Useful as a first fast CRT point for screening highly reactive systems or higher-power settings.
10	Measured value	May range from weak, soft or green-state cure to acceptable initial cure	May range from poor to moderate adhesion	Useful midpoint in a fast CRT. Often helps identify whether the resin remains under-cured or is entering the practical working window.
15	Measured value	May range from moderate cure to well-cured depending on resin speed and power	May range from moderate to good adhesion	Useful third fast CRT point. Often sufficient to bracket the likely standard-layer exposure interval in slower systems.
20	Measured value	Often enters the practical working range in slower or lower-power conditions	Usually stronger adhesion than shorter times	Useful extension point when 5–10–15 s remains too low for the target layer thickness or for slow or highly filled resins.
25–30	Measured value	May be required for slow-curing systems, filled materials or lower-power settings	Can become strong	Useful for broader CRT mapping when the practical cure window sits beyond 15–20 s.
50	Measured value	High-dose reference point	Typically strong adhesion	Useful as an additional long-exposure reference in some workflows.
75	Measured value	High-dose reference point with strong cure	Typically very strong adhesion in many systems	Often useful as a reference for initial burn-in or adhesion-layer screening.
100	Measured value	Very high-dose reference point	May be excessive for many systems	Useful only as an upper reference point in selected cases; may indicate over-cure tendency in fast or brittle systems.

Mobile: scroll horizontally to view all columns. The first column remains visible while scrolling.

Recommended practical use

Start with a fast CRT at 5 s, 10 s and 15 s.
Add 1–2 extra points only in the interval relevant to the target Z layer thickness.
For fast or higher-power conditions, this may mean adding points between 1 and 5 s or between 5 and 10 s.
For slower resins or lower-power conditions, this may mean adding points between 15 and 20 s or beyond.
Use 75–90 s only as a practical long-exposure reference for initial adhesion-layer evaluation, not as a universal rule.

9) Asiga Composer workflow (calibration phase)

Open Asiga Composer and create a new build:

Select the exact printer model and target Z layer thickness, commonly 0.050 mm or 0.100 mm.
Select a reference material profile as a starting point where appropriate.
Add the 3Dresyns calibration file 3Dtest1 (flat coin without supports).
Launch the Build Wizard or equivalent workflow.

During the calibration phase:

Set base plate thickness to 0.000 mm
Disable anti-aliasing during initial calibration
Set burn-in exposure to approximately 75–90 s as an initial reference
Leave Z and XY compensation at 0 during first calibration
Replace the default normal-layer exposure time with the value determined from your CRT at the selected power setting

Where a default Composer exposure appears in the reference profile, it should be treated only as a provisional placeholder and replaced by the value obtained from the CRT at the selected power.

10) Selecting starting print exposure settings

Use the CRT to select a structured starting point.

As a general rule, select a standard exposure that cures approximately the target layer thickness multiplied by an appropriate cure-thickness factor. The correct factor depends on the combined behaviour of the material system, including curing kinetics, green-state mechanical resistance, physical behaviour during separation and adhesion characteristics.

Fast, brittle or highly reactive resins: typically start at approximately 1.0–1.2× the target layer thickness
Slower, softer, less brittle or more peel-sensitive resins: typically start at approximately 1.3–1.5× the target layer thickness

Important note: these factors are approximate. Different resins may show different kinetic, mechanical, physical and adhesive behaviour and may therefore require different exposure margins even at the same nominal layer thickness.

Start with approximately 1.5 cured layers as a robust initial reference.
If printing is already successful and the goal is more speed or finer detail, move towards approximately 1.1–1.2 layers.
If the selected exposure is too weak for reliable printing, move towards approximately 1.75–2 layers.

Burn-in exposure should correspond to a long exposure that gives strong curing and strong adhesion under the same Asiga power conditions.

11) Validation using reference test files

Download 3Dtest1 calibration STL file
Download 3Dtest2 calibration STL file

3Dtest1 (flat coin without supports)

Confirms basic printability and provides an indication of XY resolution.

Full detachment: increase burn-in exposure and, if relevant, the number of initial layers.
Soft or tender part: increase standard exposure.
Brittle part or excessive adhesion: reduce exposure.

Optional large-area printability test: wedge

The wedge is an optional advanced test for larger parts and broad-area printability screening. It can help identify issues related to separation force, levelling and non-uniform light-power distribution across the vat. It is particularly useful when the user intends to print large parts or wants to screen comparative material rigidity, flexibility or fracture behaviour.

3Dtest2 (flat coin with supports)

This is the most demanding and most informative calibration print. It validates supported printing and enables evaluation of XYZ dimensional accuracy.

Z error (%) = (measured − theoretical) / theoretical × 100

The support tips are deliberately very small to simulate difficult printing conditions with minimum or near-minimum support contact. The flat orientation is also intentionally demanding: it may trap liquid resin and promote light bleed in the Z direction, making the back of the coin appear thicker than the theoretical 2.0 mm.

12) Quality evaluation and fine adjustment

XY resolution may be estimated by identifying the smallest readable concentric feature.
Z accuracy is evaluated by comparing measured and theoretical thickness.
If additional accuracy or detail is required, exposure parameters may be adjusted incrementally, documented and re-validated.
If the supported coin prints but appears too thick in Z, reduce light bleed by lowering exposure, lowering power where appropriate, or applying validated fine tuning.

13) Optional fine tuning

3Dresyns® resins may be optimised using Fine Tuning Additives to adjust printing speed, resolution, precision and dimensional accuracy. For deeper optimisation and extended methodology, use Fine Tuning additives for custom fine tuning of printing speed, resolution, precision, and dimensional accuracy.

14) Cleaning and post-processing

Cleaning and post-processing must follow the applicable Instructions for Use, including the general IFU & Printing Parameters for DLP & LCD printers and any material-specific or application-specific IFU where applicable.

Deviation from qualified post-processing workflows may affect surface quality, mechanical performance and long-term material behaviour.

Drying before post-curing is mandatory. Washed parts must be fully dried before final post-curing.

Most printed materials benefit from a gentle post-cure exposure to UV/visible light. Excessive light power, time or temperature during post-curing may cause yellowing in some materials, especially above approximately 60 °C.

15) Basic tools and equipment

digital caliper or micrometer,
microscope glass slides,
precision weighing balance (optional),
measurement tools appropriate to the required level of process control.

16) Advanced considerations for Asiga-specific optimisation

Advanced optimisation on Asiga systems requires careful consideration of process trade-offs:

Increasing temperature may reduce resin viscosity and peeling forces. Viscous resins may be warmed to approximately 30–35 °C where appropriate.
Increasing exposure power may improve printing speed but can reduce resolution or surface definition if not recalibrated correctly.
Changing Z layer thickness, power setting or support logic requires re-validation of the selected exposure window.
For very viscous resins, Separation Distance may be increased to allow more time for resin recovery and vat refill.
Support Exposure may be increased where necessary to reinforce support integrity during difficult prints.
Wait time after separation may be increased where additional resin flow time is needed.

Many mechanical values in Asiga workflows can remain at their predefined settings during first calibration. The most important user-controlled variables are usually power, exposure, burn-in behaviour, layer height, resin temperature and selected support strategy.

Users implementing advanced optimisation strategies are responsible for documenting final settings, maintaining traceability and validating performance for their intended application. Custom configuration or INI files may be created as part of user-defined workflows.

17) Governing principle

Printer-specific guidance for Asiga systems provides reference workflows only. Final part performance depends on the complete material–printer–process–post-processing system and must be validated by the user for the intended application.

18) Need professional support?

For printer selection, parameter definition or advanced optimisation, contact info@3Dresyns.com.

Instructions for Use (IFU) & Printing Parameters for Asiga DLP printers