High-speed resin printing

High-speed 3D printing first revolutionized FFF (fused filament) technology and is now emerging in resin printing (SLA/DLP/LCD). In FFF, specialized printers and kits (e.g., Raise3D Hyper FFF or Prusa MK4) have appeared that compensate for vibrations using input shaping, use high-flow hotends (Volcano, CHT), and new reinforced filaments to achieve actual print speeds 3–5 times higher without losing quality. For example, the Raise3D Hyper FFF kit includes firmware with resonance compensation, redesigned hotends (up to +200% flow), and Hyperspeed filaments (+50% flow), allowing aesthetic quality to be maintained while multiplying productivity. Other manufacturers (Prusa, Creality, BambuLab) have followed this trend with Klipper-type custom firmware and similar components, although real limits are still constrained by process physics (hotend flow, inertia, etc.).

Video 1: Comparison between standard and high-speed resins. Source: Phrozen.

At the same time, resin printing is seeing a push toward higher speeds: resins and systems are sought that cure layers faster and detach with less effort. Unlike filament, bottlenecks in resin are the photo-curing time of each layer (the UV exposure time needed for hardening) and peeling forces (adhesion between the cured part and the membrane). Advances include highly reactive, low-viscosity resins (to reduce exposure times) and specialized bottom films that reduce adhesion. For example, high-performance printers combine intense light sources (405 nm, >3000 µW/cm²) with optimized firmware, while “Fast,” “Speed,” or “Draft” resins (Anycubic High Speed, Phrozen Speed, Raise3D Draft, etc.) cure in a few seconds and flow quickly to avoid local overheating that could damage the print.

Image 1: Models printed with high-speed resin. Source: Anycubic.

Standard resins vs. high-speed resins

Diving deeper into fast resins, these are formulated and designed to cure with very short exposures, achieving better print times. This usually requires two approaches: on one hand, reducing viscosity so the resin can flow quickly, and on the other hand, increasing chemical activity to reduce exposure and curing times.

Image 2: Models printed with high-speed resin without quality loss. Source: Raise3D.

This allows large models to be produced in just a few hours. In general, fast resins share properties: low viscosity, high stiffness after curing (to form each layer quickly), and high UV sensitivity, with pigments optimized for rapid curing. Special mention goes to the Raise3D Draft formulation, which additionally helps dissipate heat during Z-axis movement, improves solubility in alcohol, and produces rigid parts with excellent detail.

Image 3: The lower viscosity of high-speed resin allows greater flow. Source: Anycubic.

In contrast, standard resins have higher viscosity and require longer exposures, making them suitable for detailed prints or less time-sensitive jobs. When moving to high-speed resin printing, it is essential to select appropriate materials and machines: rigid resins formulated to cure quickly, a powerful light source (405 nm LED/LCD with high irradiance), and thicker layers (0.1 mm or more) that cover geometry rapidly. In many cases, a standard 0.05 mm layer height can be replaced with 0.1 mm or more, drastically reducing the number of layers (and total time) without excessively losing resolution.

Release films: FEP, nFEP (PFA), and ACF

Once suitable resins are chosen, the other limiting factor for print speed is peeling forces. The bottom film (often FEP) plays a key role: it is the interface where each layer peels. There are several types:

Image 4: Difference in peeling forces of different films. Source: Phrozen.

FEP (Fluorinated Ethylene Propylene):

The most common film. It has good transparency but high adhesion to cured resin. Peeling each layer generates strong forces, requiring slow and long platform lifts, limiting speed and potentially causing print defects (striation, delamination).

Image 5: FEP sheets for 3D resin printing. Source: Prusa3D.

nFEP or PFA (Perfluoroalkoxy):

A material similar to FEP but with a less adhesive surface. Its release force is lower, improving separation. PFA (sometimes called nFEP) is recommended for fast printing.

Image 6: nFEP sheets facilitate layer release. Source: Elegoo.

ACF (Aorita Composite Film):

A newer, advanced film designed specifically for high speed. Its ultra-smooth, non-stick surface significantly reduces peeling forces compared to FEP/PFA. This allows faster printing with minimal platform lift distance: the platform can rise less per layer without sticking, reducing stress on parts.

Image 7: ACF sheets reduce peel forces and enable faster printing. Source: Phrozen.

In summary: ACF outperforms FEP and PFA (nFEP) in speed and reliability. Studies show ACF drastically reduces peel force and prevents adhesion voids, allowing higher speeds without compromising quality. High-reactivity resins (e.g., AmeraLabs XVN-50) should only be used with tanks featuring FEP, PFA/nFEP, or ACF bottoms.

Higher adhesion means more energy (time) is lost with each platform lift, directly impacting maximum speed. To avoid this, in addition to using high-speed resins and low-adhesion films, other optimization strategies include:

• Adjusting lift height: Fast printers typically use minimal lifts (e.g., 4–5 mm instead of 6 mm standard), just enough to detach parts without friction. Less distance = less movement time.
• Increasing lift/retraction speed: For low-viscosity rigid resins, lift speed can be maximized (while avoiding support damage), accelerating the layer cycle.
• Optimizing dead times: Reduce or eliminate idle delays between exposure/lift/retraction to save seconds per layer. For example, pre-lift rests are ~0.5 s minimum, and post-retraction 0 s for liquid resins. Small reductions accumulate over dozens of layers.
• Use of permeable membranes: Industrial technologies (e.g., Carbon DLS) use oxygen-permeable membranes to nearly eliminate adhesion (print peel-free). Not common on desktop printers, but shows the trend: less adhesion = higher speed.

It is also important to select the appropriate equipment: a printer with fast firmware and precise control (monochrome LCD or high-performance 405 nm DLP) with quick-release systems, such as the Raise3D DF2+ or Heygears UltraCraft A2D HD.

In summary, Liqcreate identifies eight key factors for fast resin printing:

• Fast resin and printer: 3D printer with powerful light source (405 nm) and high-reactivity resin (e.g., Liqcreate Premium Model).
• Layer thickness: Thicker layers (0.1–0.15 mm) significantly reduce the number of layers.
• Fewer base layers: 1–2 bottom layers are sufficient for minimal adhesion, avoiding extra “burn-in” time.
• Less waiting time: Minimize pauses before/after platform lift, especially for liquid resins.
• Minimal lift height: Adjust lift to the point where the part actually detaches (e.g., 4–5 mm).
• High lift speed: Increase lift speed if resin allows; reinforce supports if necessary.
• High retraction speed: Retract platform quickly to move to next layer; suitable for rigid/glassy resins.
• Low-adhesion film: Use PFA/nFEP or ACF.

Following these guidelines allows significant increases in printing speed without risking part success. For example, using a fast resin and a powerful LCD, 20 cm dental templates have been printed in ~20 minutes, impossible with standard resin.