Six service bureaus run Axtra3D's hybrid resin printing for high-mix work

Service bureaus including Protolabs, Dinsmore, Met-L-Flo, Laser Prototypes Europe, Prinoa and Prototek use Axtra3D's Hybrid PhotoSynthesis resin process on the Lumia X1. Axtra3D pairs the printer with wash and cure units, build software and a data system, aimed at the high-throughput, high-mix output of polymer services.

Context Hybrid PhotoSynthesis is Axtra3D's photopolymerization process that combines a DLP light source for fast curing with a laser for fine detail.

What does the Axtra Workflow include?

The Lumia X1 is the core of the offer. It combines Hybrid PhotoSynthesis with TruLayer Separation, a sensor-embedded glass plate below the membrane that speeds up layer detachment, and TruLayer Adaption, which adjusts the plate's flatness during the build to keep resin layer thickness consistent. The build volume is 249 x 140 x 495 mm on a footprint of 800 x 800 x 1800 mm. Axtra3D cites over 70% capacity use and 90% uptime for lights-out production.

Around the printer sit Axtra.Wash, an automated cleaning station with profiles by material, and Axtra.Cure, which offers thermal and UV curing with automated parameter selection. Services may use their own post-processing instead.

Software and materials

Volume, Axtra3D's build preparation software, covers orientation, supports, material selection, slicing, simulation and time estimates. Third-party build software can be used instead. Axtra.Insight collects data from over 155 on-board sensors across the production chain to support troubleshooting, repeat orders and process improvement.

Over 25 materials are qualified on the Lumia X1, from Henkel, Arkema, ForwardAM and 3D Systems, plus dental resins from Keystone, Pro3dure and NextDent, casting resins and general-use resins. Material changes take about 10 minutes. Axtra Solutions is the turnkey option with validated profiles, while Axtra OpenAccess allows unvalidated materials and own parameters.

How do the service bureaus use it?

Protolabs in Minnesota bought its first Lumia X1 in 2024, has since added two more and qualified Medical White (MED-WHT 10). It prints injection mold inserts and electrical connectors. Met-L-Flo in Illinois makes insert molds and, as of 2024, molded over 500 parts per printed mold set.

Dinsmore in California, part of the ADDMAN Group, printed an artery stent with 100 micron layers and a weight of 2.97 grams in under an hour, at $0.53 per part. Laser Prototypes Europe in Belfast uses the large build volume for bigger parts with fine detail. Prinoa in Germany focuses on dental devices such as splints, crowns and bridges. Prototek is also named as a user.

What it means

For small and mid-sized manufacturers, the relevant point is that a service bureau's equipment choice shapes what they can order: printed mold inserts, fine-detail parts and dental devices are all in this fleet. Figures such as 90% uptime, 500 molded parts per tool set and $0.53 per stent come from Axtra3D and its partners, so they are worth confirming on one's own geometry and material before a business case relies on them. It also continues Axtra3D's recent workflow and resin-listing news.

Frequently asked questions

Which service bureaus use Axtra3D's Hybrid PhotoSynthesis?

The report names Protolabs, Met-L-Flo, Dinsmore, Laser Prototypes Europe, Prinoa and Prototek.

How many materials are validated on the Lumia X1?

Over 25 materials have validated print profiles, with material changes taking about 10 minutes. Users can also work with unvalidated materials through Axtra OpenAccess.

What is the build size of the Lumia X1?

The build size is 249 x 140 x 495 mm, and the machine footprint is 800 x 800 x 1800 mm.