Form 4L - LFD 3D printer

The Form 4L 3D printer by Formlabs marks a significant advancement in SLA 3D printing technology on a large scale. Designed for high-speed, high-volume manufacturing, this printer delivers exceptional workflow adaptability alongside superb precision and quality, rivaling traditional injection molding methods.

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

The Form 4L uses MSLA technology (Masked Stereolithography), which equips it with an incredible printing speed of up to 80 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 4L can achieve high levels of precision in 3D prints. The printing engine of the Form 4L, 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 4L uses a Light Processing Unit 4L (LPU 4L) 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 145 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 46 μm and preconfigured anti-aliasing allows for sharp details, smooth surface finishes, and tight tolerances (XY ±0.15 %).

Image 1: The Form 4L completes most 3D prints in under 6 hours. Source: Formlabs.

The Form 4L has a build volume of 353 x 196 x 350 mm (24.2 liters), a build area of 692 cm² and average allowed model height of 87 mm. These parameters make for 4.6 larger build capabilities compared to the Form 4 and Form 4B printers at impressive print speed of up to 80 mm per hour. These features enable most large-format 3D prints to be completed in under 6 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 4L 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 4L 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 Form 4L 3D printer has capacity for 2 resin cartridges in order to make uninterrupted large-scale additive manufacturing possible. Switching between cartridges for multimaterial printing is done in under 1 minute. 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 4L 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 cartridges' load cell sensors facilitate material changes and help minimize waste. Users can print parts without worrying about the Form 4L 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 4L comes with validated settings for many advanced materials. Source: Formlabs.

The six control systems of the Form 4L 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 4L’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 4L 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 4L 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 4L 3D printer can be purchased with either a basic package or a complete package. The basic package includes: a Form 4L printer, a Form 4L resin tank, a Form 4 Mixer, a Form 4L build platform, and a Formlabs 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 the resin pumping system, the Form Wash L station (2nd Gen), the Form Cure L station, and one year of services (warranty and Pro Service Plan).

Reliability and Versatility

The Form 4L is specifically engineered for high-volume additive manufacturing, whether for batch production or printing large parts in a single run. With its unrivaled speed and significantly expanded print volume, it excels in industries such as automotive and transport, aerospace, industrial manufacturing, consumer goods, and education and research.

Image 4: Laptop chassis 3D printed with the Form 4L printer. Source: Formlabs.

Regardless of the resin type or operational demands, the Form 4L consistently produces parts of exceptional quality. Its reliability, precision, and high-speed performance, combined with the capability to handle a wide range of materials, make it one of the best solutions for large-scale resin 3D printing. This printer is a powerful asset for manufacturers seeking batch production or the creation of large, complex parts, while adapting seamlessly to evolving user needs.