Form 4 - LFD 3D printer

The Form 4 3D printer from Formlabs represents the next step in the evolution of SLA 3D printing. This printer allows production at incredible speeds, offering a high degree of workflow flexibility and quality and precision comparable to injection molding.

Video 1: The Form 4 3D printer. Source: Formlabs.

The Form 4 uses MSLA technology (Masked Stereolithography) known for its incredible printing speed of up to 100 mm/h and the ability to work with an extensive catalog of leading resins in the 3D printing industry for countless applications.

Enhanced Technology

MSLA technology uses a mask to direct ultraviolet light onto a photosensitive resin. This mask creates a precise illumination pattern, curing the resin only in the desired areas. As a result, the Form 4 can achieve high levels of precision in 3D prints. The printing engine of the Form 4, with Low Force Display™ (LFD) technology, is based on the previous Low Force Stereolithography™ (LFS) model, but with many improvements. LFD technology improves printing speed and avoids issues that might occur with LFS technology.

Video 2: LFD technology. Source: Formlabs.

The Form 4 uses a Light Processing Unit 4 (LPU 4) which, unlike the previous LPU, is more durable (750,000 layers) and features a set of polarizers and optical films, and a custom-made liquid crystal display. All these elements help to reduce separation forces, improving print quality. The backlight unit features 60 LEDs with uniform wavelength, a set of plano-convex lenses, integrated air cooling, and a wave power of 16 mW/cm² applied to the curing plane. The high-resolution LCD screen with an XY resolution of 50 μm and preconfigured anti-aliasing allows for sharp details, smooth surface finishes, and tight tolerances.

Image 1: The Form 4 completes most 3D prints in under 2 hours. Source: Formlabs.

The Form 4 has a build volume of 200 x 125 x 210 mm (5.25 liters) and a print area of 250 cm², allowing for parts up to 27.3 cm in length. It features a 30% larger build volume compared to previous printers and an impressive print speed of up to 100 mm per hour. These features enable most 3D prints to be completed in under 2 hours, two to four times faster than any other resin printer in the Form series, even when printing large parts or batches.

Compatible Materials

In addition to the extensive existing resin portfolio from Formlabs, the Form 4 can work with six entirely new resins offering better speed, toughness, accuracy, and aesthetics. The general-use V5 resins (Clear, Grey, Black, White) enable printing two to five times faster than the Form 3, with improved strength and color. The Fast Model resin is ideal for rapid prototyping and orthodontic model production, while the Precision Model resin is for dental models. Additionally, the Form 4 features the optional Open Materials Platform Open Platform that allows users to use certified third-party resins, set custom print settings, and have complete freedom to print with any 405 nm photopolymer resin.

Image 2: The new resin cartridge design is more efficient and sustainable. Source: Formlabs.

The redesigned cartridge allows for faster resin dispensing, filling an empty tank in just 2 to 8 minutes, thanks to a newly designed valve system that speeds up the process by 5 to 10 times compared to the Form 3. Additionally, the new cartridge design uses 63% less plastic, reducing waste while still reliably holding one liter of resin. Its form factor has also been optimized, making it 30% smaller and saving valuable space.

Ease of Use

The Form 4 also stands out for its ease of use, as learning to operate it only takes about 15 minutes. It features automatic and intelligent part orientation and has an advanced support generation capability. The integrated resin dosing system, validated print settings, and the cartridge's load cell sensor facilitate material changes and help minimize waste. Users can print parts without worrying about the Form 4 running out of resin. The improved resin dispensing and heating capabilities allow Formlabs to develop advanced materials that were previously out of reach, such as those with very high viscosity or high filler percentages.

Video 3: The Form 4 comes with validated settings for many advanced materials. Source: Formlabs.

The six control systems of the Form 4 also help facilitate the use of this printer: they maintain temperature and resin levels, printing forces, Z-axis leveling, and printing status in optimal conditions. The Form 4’s sensors alert users to potential issues that may arise during printing through automatic diagnostics and ensure the printer's longevity.

Video 4: The 3D printing workflow with the Form 4 printer. Source: Formlabs.

Printer maintenance is streamlined thanks to preventive maintenance reminders and the free Dashboard software. Compared to the previous model (the Form 3), the Form 4 is also more autonomous and intelligent, as it features WiFi, Ethernet, and USB connectivity, enabling coordination of complex 3D printing workflows. Additionally, thanks to the integrated 5 MP camera, users can check their prints live, and the intuitive user interface is displayed on a 7-inch touchscreen.

Available Packages

The Form 4 3D printer can be purchased with either a basic package or a complete package. The basic package includes: a Form 4 printer, a Form 4 resin tank, a Form 4 Mixer, a Form 4 build platform, and a Form 4 Finish Kit. The basic package also includes a one-year warranty and the Preform software installed.

Image 3: Basic and complete package. Source: Formlabs.

The complete package includes all the previously mentioned items plus a Flex build platform (instead of the standard one), the Form Wash station (2nd Gen), the Form Cure station, an automatic solvent pump, and one year of services (warranty and Pro Service Plan).

Reliability and Versatility

The Form 4 creates new opportunities across all types of uses, with unmatched speed and a much larger print volume than previous printers. This makes it very useful in various sectors, such as automotive and transportation, aerospace, manufacturing and industry, consumer products, and education and research.

Image 4: Surgical ratchet printed in 3D with the Form 4 printer. Source: Formlabs.

The quality of the parts produced with the Form 4 is virtually impeccable, regardless of the resin used or the printer's usage. The reliability and precision, along with the incredible speed of printing and the versatility of materials that can be used, make the Form 4 one of the best options for 3D resin printing, a very powerful additive manufacturing tool that evolves alongside the user and adapts to their needs.