At Purdue University Fort Wayne, the mechanical engineering lab is a hub of innovation and practical learning. Under the guidance of Dale Ruppert, Mechanical Engineering Laboratory Technician, students and faculty leverage the Raise3D DF2’s advanced DLP resin 3D printing technology to enhance learning experiences, explore new applications, and solve real-world engineering problems.
In this case study, we explore how Purdue University Fort Wayne selected and utilized Raise3D’s DF2 resin printer, highlighting how it has broadened the university’s engineering and research capabilities. Through real-world applications and hands-on student experiences, Purdue University Fort Wayne demonstrates the transformative potential of integrating 3D printing resin DLP technology into engineering education.
Why Raise3D DF2? Precision, Speed, and Reliability
With extensive experience in managing Raise3D FFF printers (also known as FDM) in the lab, Ruppert was keen on expanding into resin printing technology. Proven quality and reliability of Raise3D’s Pro2 series naturally led him to consider Raise3D’s (true DLP resin printer, the DF2. He highlighted the DF2’s exceptional print speed as particularly valuable, allowing increased student productivity and higher volume of completed parts more efficiently.
Ruppert explained that his positive experience with the Raise3D brand heavily impacted his decision to purchase the DF2: „We do have a significant amount of Raise3D FFF printers in our lab, and they have been very reliable, very good printers for us. Once I saw that Raise3D had their own resin printer, that instantly made that go up to the top of my list of resin printers.“
Real Results in Classroom from Mascot to Automotive Parts
One of the early demonstrations of DF2’s capabilities involved printing a detailed model of Purdue University Fort Wayne’s mastodon mascot, immediately showcasing the printer’s exceptional quality. However, real-world applications extend far beyond simple models:
- Reverse-Engineered Components: Students successfully reverse-engineered and printed plastic brackets for computer monitors, achieving greater strength and consistency than the original molded parts.
- Automotive Innovation: An actuator component for a 2010 Ford automobile was re-engineered and printed using the high-performance Henkel Loctite PRO476 resin, proving superior in durability and mechanical performance compared to OEM parts.
- Small, Precise Parts: Students were able to print a small engineering component with a hole that was tiny in diameter, showing promise for future high-precision projects.
These projects not only illustrate the printer’s capabilities, but also underscore its significant educational value, bridging classroom theory and practical, industrial application.
Exceptional Precision and Detail of DLP Technology
The adoption of DLP technology over previous LCD printers has significantly improved the precision of the lab’s outputs. Raise3D’s DF2 leverages advanced DLP technology to deliver exceptionally high-resolution prints with consistent accuracy. Compared to LCD, the high-quality DLP projector offers a longer lifespan, ensuring reliable results over time. Ruppert emphasized this capability, noting its critical importance for engineering applications.
„We like to have more accuracy with our prints, so the DLP technology has been great... Having technology that lets us get down to very small specifications was very encouraging.“
This precision enables the production of intricate projects, including fine-detail components for precise temperature measurement devices, and highly detailed architectural models for educational demonstrations.
Safe and Clean Workflow with DF2’s Smart Features
Ruppert praised the DF2 Solution’s automated workflow and cleanliness— the critical factors in an educational environment. The RFID chip-managed print, wash, and cure process dramatically reduces direct handling of resins, maintaining safety standards, and operational efficiency. Ruppert particularly appreciated the self-filtering system for isopropyl alcohol waste, easing environmental concerns and enhancing lab safety.
Having been warned by fellow colleagues that the resin printing process will be messy, Ruppert was pleasantly surprised by the hands-off nature of the DF2 Solution. „I love how streamlined it’s all been. Essentially, it’s plug and play—you put in the file you want, it has all the templates built in; it has all the settings as far as washing and curing for that particular model. The streamlined aspect of the DF2 has been great when using this with students and for classes.“
Intuitive Software Experience with ideaMaker
Ease-of-use extends beyond the DF2’s hardware. Raise3D’s ideaMaker software simplifies resin management with built-in templates and flexibility for custom settings. Ruppert appreciates the software’s intuitive design, allowing for quick setup and seamless operation:
„I really like how the resins have their own templates built into the software. It’s made it very easy—when I put the model into the software, I essentially can tell it what resin I want it to use, and there’s already a template built-in.“
Exploring New Applications with the Open Material Program
Additionally, Ruppert highly values Raise3D’s Open Material Program (OMP), which enables experimentation with diverse resins beyond standard brands. He plans to utilize OMP to test mechanical properties of various materials, further enriching the university’s research capabilities and student learning opportunities:
„I would love to get to the point with this printer where I could create my own templates and experiment with different resins we didn’t previously know about.“
Transforming Educational Experiences with Raise3D DF2
Introducing the DF2 Solution has significantly broadened Purdue University Fort Wayne’s educational horizons, allowing students to experience advanced manufacturing processes firsthand. The printer’s high precision and versatile material compatibility have opened new doors for student innovation, research projects, and real-world applications. As the lab continues to integrate the DF2 into coursework and collaborative projects, it promises to further enhance students‘ practical skills, preparing them to be future industry leaders and innovators.
Ruppert encapsulated this transformation succinctly: „This has really changed this whole lab and the experience for our students. I’ve been very happy with this whole system, and really, we’re just at the tip of the iceberg.“
