3D SLA resin-prints (not Fusion Deposition Modeling - fDM)

3D resin-printing: PKG uses a 4K UV Lubricant Sublayer Photocuring (LSPc) resin-print process. 

Quality 3D LSPc parts have neat edges, smooth surface finishes, 50-100 micron layer-lines, closer tolerances and much better dimensional stability than thermoplastic Fused Deposition Modelling (FDM).  As such, PKG parts cannot be made with a consumer-grade 'hot-melt filament' printer producing uneven parts intolerant to heat and/or UV light. Our resin-printed parts are tough and perfectly suited to kitplane accessory parts manufacture.

3D LSPc is ideal for intricate details (like hollows, galleries and small hexagonal nut holes) that 'subtractive' billet milling processes can't achieve either at all, or on a minute scale or slow enough cut rate to an acceptable price-point. Optionally, injection-moulded parts need to be produced by the tens of thousands to be viable, but our small kitplane market can't satisfy that demand. Hence PKG parts aren't mass produced anywhere else because they can't be made at low-rate production without going broke in the process.

Customers may be surprised that some parts seem relatively expensive for "3D printing", often dearer than mass-produced CNC and/or injection moulded parts, but for good reason. Quality 'additive' 3D LSPc isn't a quick or convenient production process; requiring much more direct labour, a highly advanced printer, liquid resins costing USD$270-$1100/kg, print-time, resin waste (numerous pillars or lattices to support overhangs and prevent distortion), 100% IPA-wash (to remove excess liquid resin), 100% IPA rinsing, drying, 30-90min UV post-cure, support removal, 800-grit wet finish-sanding and hazardous material handling.  In short, SLA resin-printing is a smelly, hazardous, expensive and labour intensive capability; but the practical, well-finished products are worth the effort.

Firewall forward: At around $500/kg, BASF's xPRO9400-FR (flame retardant) resin is purpose designed for hot environments. It is strong, halogen-free and handles temperatures of 250°C (482F) with a UL 94 V-0 rating, meaning parts won't melt, drip or sustain a flame for more than 10 seconds after being subjected to blow-torch abuse.  xPRO9400-FR is an ideal resin for our engine bay baffle heating and NACA ducts, cooling shrouds, ignition harness clips and similar parts.