Form 4BL - LFD 3D printer

The Form 4BL 3D printer from Formlabs is an advanced SLA 3D printing solution for large-volume additive manufacturing in the medical and dental sectors. This printer allows production of large-sized objects or batches of dental models, surgical guides, aligners, splints, crowns and bridges, and more, at incredible speeds and with unmatched accuracy, offering a high degree of workflow flexibility, higher throughputs, and high patient satisfaction.

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

The Form 4BL uses MSLA technology (Masked Stereolithography) known for its 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, including biocompatible dental and medical uses.

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 4BL can achieve high levels of precision in 3D prints. The printing engine of the Form 4BL, 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 4BL 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.

Image 1: The Form 4BL can print even 32 dental models in only 14 minutes. Source: Formlabs.

The Form 4BL has a build volume of 353 x 196 x 350 mm (24.2 liters) and a print area of 692 cm². It features a 30% larger build volume compared to previous printers from the Form series, and an impressive print speed of up to 80 mm per hour. These features enable the Form 4BL printer to complete a build plate of 32 dental models in 14 minutes.

Compatible Materials

In addition to standard materials, the Form 4BL resin 3D printer is compatible with a broad range of biocompatible materials for dental and medical applications, both from Formlabs as well as from third-party manufacturers. This allows to use dentistry materials such as Surgical Guide resin, Premium Teeth resin, Denture Base resin, Dental LT Comfort resin or Custom Tray resin, as well as materials from Formlabs' BioMed line for biocompatible applications: BioMed Clear, BioMed Durable, BioMed Amber, BioMed White and Black, BioMed Elastic 50A and BioMed Flex 80A. Furthermore, Formlabs offers comprehensive support services for the dentistry sector through the Dental Service Plan (DSP) and the Formlabs Dental Academy.

Video 3: Custom impression tray printed on the Form 4BL printer. Source: Formlabs.

In addition to the extensive existing resin portfolio from Formlabs, the Form 4BL 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 4BL 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. This feature is exceptionally valuable for dental and medical labs as it allows for freedom in material choice for any application.

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

The six control systems of the Form 4BL 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 4BL’s sensors alert users to potential issues that may arise during printing through automatic diagnostics and ensure the printer's longevity.

Video 5: The 3D printing workflow with the Form 4BL 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 4BL is also more autonomous and intelligent, as it features WiFi, Ethernet, and USB connectivity, enabling coordination of complex 3D printing workflows. It requires up to 3 times fewer user interactions than the Form 4B printer, which is great time saving in busy production 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 4BL 3D printer can be purchased with either a basic package or a complete package. The basic package includes: a Form 4BL printer, a Form 4BL resin tank, a Form 4BL Mixer, a build platform L, and a Form 4BL Finish Kit. The basic package also includes a one-year warranty, a 1 year Dental Service Plan (DSP), and the Preform software installed.

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

The complete package includes all the previously mentioned items plus a resin pumping system, the Form Wash L station (2nd Gen), and the Form Cure L station. Similarly to the basic package, the complete package also comes with a one-year warranty, a 1 year Dental Service Plan (DSP), and the Preform software installed.

Reliability and Versatility

The Form 4BL 3D printer is specifically engineered for dental and medical applications, boasting a rapid printing speed of 80 mm/h, which allows for the production of up to 32 dental models in just 14 minutes. Its large build volume accommodates a variety of applications, while the wide selection of standard and biocompatible materials, along with an open material platform, provides versatile customization. 

Image 4: The high final model accuracy ensure a perfect fit and patient satisfaction. Source: Formlabs.

Excellent connectivity options, including WiFi and Ethernet, enhance workflow efficiency, making it easy to integrate into busy dental and medical labs. Designed for user-friendliness, the Form 4BL features a straightforward learning curve and simplifies post-processing. This printer supports same-day dentistry and the creation of customized one-off parts, ensuring exceptional accuracy and alignment with CAD models, while also delivering an outstanding surface finish.