If you don’t already know me, I am an Additive Manufacturing Specialist (a fancy name for a 3D printing expert) at EAC Product Development Solutions.

I specialize in Formlabs 3D desktop printers and often give tips and tricks to help you make the most out of your 3D printer investment. Follow me on my LinkedIn for more tips and tricks!

I receive quite a few emails on part orientation and would like to share with you a tip using PreForm, Formlabs’ free 3D printing software.

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Download PreForm for Mac. 
See Requirements for OS X 10.10 or higher

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See Requirements for Windows 7 (64-bit) or higher

Part Orientation using PreForm Software

In this tip, I’ll show you how you can be more successful with your prints using Formlabs printer software. The software is very intuitive and I love sharing what I’ve learned to make things easier for those using the Form 2 or Form 3 SLA printers!

Watch my video or read the transcript below!

Transcript from Tip Video

 I have PreForm open here and I have Go Pro mount clip imported for us to use as our model today. I just want to show you guys a couple of quick things here.

Step 1: Open file of model

Off to the left side, we have our Quick Access menu buttons and off to the right side, we have our status bar showing us the print time, how many layers are printing, the volume, printability of the model, etc.

Step 2: Get familiar with the software

What we want to do when we get started is to make sure our model is set up how we want it to be. I want to make sure it’s oriented properly. So what I can do is click on it to select it, once it’s blue, it shows that it’s selected. I’m going to drag it to tilt the model.

Step 3: Click on model to select (should appear blue)

You can even use the directional key to move it over to each side if you want to place more of the parts on the build platform.

With parts that have these larger, flat surface areas – you’ll want to tilt them at an angle of at least 10-20 degrees to improve your success rate for printing. Printing at an angle reduces the surface area of each layer which in turn creates less force on the part.

Step 4: Tilt model at an angle

Now that we have it oriented properly, we’ll want to create the supports. I’m going to go to the left side to the support button on the Quick Access menu – to generate all of them automatically. You can manually add them if you’d like. It only takes a minute to generate the supports for you.

Step 5: Generate the supports for your model

Once the supports are generated, you’ll want to take a look at the model and make sure it’s set up the way you want it to be.

Step 6: Approve/Modify generated supports

Once you’re satisfied with the model, you’ll just click on your printer button on the left side where the Quick Access menu is, choose the desired printer, and then you upload the job to your 3D printer.

Step 7: Send model to printer

Interested in learning more about 3D printing on the shop floor?! Watch our free educational video on finding more opportunities for additive manufacturing.

If you’re wondering how the Form 3 compares to the Form 2, we’re able to tell you the differences between the two Formlabs 3D printing machines.

First, we’ll talk about the most common types of 3D printing since Formlabs is changing the game with a new type of 3D printing technology with the Form 3 and Form 3L. Let’s talk about the differences in these additive manufacturing processes.

Types of 3D Printing

Stereolithography (SLA): a type of vat polymerization where liquid photopolymers resin cures under ultraviolet (UV) light; highly accurate and precise prints; builds 3D layers from the bottom up with support structures.

Digital Light Processing (DLP): the oldest type of 3D printing; a type of vat polymerization where liquid plastic resin cures under LED light; less quality/detail but faster print times than SLA printers.

Fused Deposition Modeling (FDM): most widely-used process; built layer by layer where the thermoplastic filament is heated to melt into a 3D object; slow 3D printing process, but can print large-scale.

Selective Laser Sintering (SLS): uses high-power lasers to fuse particles of powdered substances together; highly accurate and precise prints like SLA printing; builds light-weight prints with no support structures.

Selective Laser Melting (SLM): uses a high-powered laser beam to fuse and melt metallic powders together; used for complex geometries, thin-wall structures; popular uses in aerospace and medical industries.

Electron Beam Melting (EBM): main use is for metal 3D printing; uses powerful electron beam in a vacuum; uses powder bed fusion technique similar to SLM; used for strong, durable 3D prints.

Laminated Object Manufacturing (LOM): heat and pressure fuse plastic, paper, or metal – cut to shape with computer-controlled blade or laser; most affordable and fastest 3D printer used for large-scale rapid prototyping.

The newest type of 3D printing, created by Formlabs, is called:

Low Force Stereolithography (LFS): advanced SLA using a more flexible tank with lower force for even more accurate and precise prints; builds 3D layers from the bottom up with easily removable support structures.

Read more about LFS 3D printing in our blog, Formlabs Releases New 3D Printers using LFS Technology.

Form 2 SLA vs Form 3 LFS

One of the benefits of printing with LFS technology is that the flexible tank significantly reduces stress on parts and prototypes during the peeling process. This results in much clearer parts with an improved surface finish as shown in the following comparison photos of a Form 2 and Form 3 print.  

Lower forces with LFS also allows you to capture fine detail and smooth surfaces with minimal layer lines which results in improved quality prints and overall reliability.

Watch our step-by-step workflow 3D printing with the Form 3 to see Formlabs present on their newest technology!

Look back to my blog on the most frequently asked questions about the Form 2, Form 3 and the Form 3L. Please reach out if you have any questions and don’t forget to follow me on LinkedIn for more news in the additive manufacturing industry!

The next generation of Stereolithography (SLA) 3D printing is here… and we’re here to tell you about it!

Formlabs introduced two new printers, the Form 3 and the Form 3L, using a process called Low Force Stereolithography (LFS) to bring you advanced 3D prints. This new additive manufacturing technology gives you the ability to create better and more affordable parts and enables production-ready applications with higher production volumes.

Let’s get down to the basics. 

What is stereolithography (SLA) 3D printing? 

The SLA 3D printing process is known for creating a smooth surface finish and detail using a laser to cure solid isotropic parts of liquid photopolymer resin. The Form 2 SLA 3D printer process allows for lower production costs to manufacturers than most 3D printing industrial machines and it leaves a smaller footprint by using less material. 

What is Low Force Stereolithography (LFS)? 

Low Force Stereolithography (LFS) is an advanced form of SLA printing that uses a flexible tank and linear illumination to turn liquid resin into flawless parts. LFS technology produces all the benefits of SLA technology plus the following features: 

Low Force Flexible tanks work by the build platform pulling up the part and gently releasing it from the film. When you have a more flexible tank, you get lower force, which allows for better print quality and better printer reliability. Lower forces on the part lead to incredible detail and surface finish, easier support removal, and cutting-edge material possibilities.  

The Components of LFS 3D Printing  

Condensed optics module: A custom-designed Light Processing Unit (LPU) inside the printer uses a compact system of lenses and mirrors to deliver accurate, repeatable prints. 

Flexible Tank: The bottom of the resin tank is a flexible surface that enables a massive reduction in peel forces while printing. 

Linear Illumination: The high-powered laser from the LPU coupled with the parabolic mirror provide a crisp completely perpendicular curing source during the LFS 3D printing process. 

The Benefits of LFS 3D Printing  

How linear illumination creates precision and uniformity with parts  

Linear Illumination = Precision + Uniformity = Accurate, Repeatable Parts 

One galvanometer positions the laser beam in the Y direction. The beam is then directed to a fold mirror and parabolic mirror so the beam is: 

1) Always directed perpendicular to the build plane (uniformity/consistency) 

2) Always moving in a straight line (precision/accuracy) 

What is an LPU and why does it matter?  

The LPU is one of the most revolutionary components of Formlabs’ LFS 3D printing technology. The Form 3 contains 1 LPU unit where the Form 3L contains 2. 

The LPU holds the laser, the galvanometer, and a system of lenses and mirrors. The parabolic mirror maintains a perpendicular path to the bottom of the resin tank at all times, making for consistently clean, crisp edges and smooth surfaces. 

The LPU is a single replaceable part located in the main printer body that folds almost every optical component of the printer into a small metal housing unit.  

Rather than containing two galvanometers like the Form 1, Form 1+, and Form 2, the LPU contains just one galvanometer that controls the direction of the laser, as the entire LPU unit moves across the build area. 

The main four components of an LPU galvanometer are the fold mirror, the laser, the parabolic mirror, and the galvanometer. 

Features of a Light Processing Unit (LPU)  

Now that you know how Low Force Stereolithography works, you’re better informed on how you can use Formlabs’ new 3D printers, the Form 3 and the Form 3L.

Reach out if you have any questions, and don’t forget to follow me on LinkedIn to check out my tips and tricks on how to use Formlabs 3D printers and trends in the additive manufacturing industry!

The Form Wash is designed for the Form 2 3D printer from Formlabs to automate the cleaning process between printing parts. It makes things much easier for engineers who don’t want to waste any time cleaning their prototypes so they can either use the Form 2 again for another print job or get back to their next project.

Washing printed parts before post-curing helps to remove excess residual resin from part surfaces and cavities. Formlabs suggests using isopropyl alcohol (IPA) as the solvent that is most compatible with washing.

If you take a look at the image above, you can see that the left part is much cleaner and visually is more detailed than its counterpart. After using the Form Wash, you can typically use the Form Cure to expose printed parts to light and heat to stabilize the parts for performance. Using the Form Cure is not necessary but using the Form Wash and Form Cure together is recommended for optimal finishing.

Colder Products Company (CPC) has trusted EAC for years to provide them multiple Form 2 printers and other Formlabs equipment and materials to rapidly prototype customized quick disconnect couplings, fittings, and connectors for plastic tubing used around the globe. We answer a few questions that users have about the Form 2 and also include an engineer’s intake as well. Here is how Jeff Martin, an applications engineer at CPC, uses the Form Wash in-house to reduce time spent cleaning 3D printed parts.

How much time does it take for one wash?

Formlabs says that most resins require washing for the Form Wash default programmed time, which is 10 minutes – although additional time is needed for some resins. The following table shows Formlabs’ recommended wash times for each resin being used.

Jeff suggests that you should set your wash time at 20 minutes for each wash. He also recommends that it’s best to physically have 2 Form Washes in-house to speed up the cleaning process, “The first Form Wash set to 10 minutes to wash parts hanging from the build platform, and the second Form Wash is used to clean the parts broken free from supports.” (Keep in mind, he typically uses Rigid Resin for his 3D prints).

What’s the best way to wash prototypes?

If you’re using the Finishing Kit, Formlabs recommends that you should wash your prototypes in at least two standard wash tanks  – the first wash, being the ‘dirty’ wash, would take 10 minutes and then the second wash, using a cleaner tank, for another 10 minutes. Once the first tank gets dirty, you can dispose the IPA, transfer the second tank into the first tank, and then pour new alcohol into the second tank.

The Finishing Kit includes 2 wash tubs to manually clean your 3D prints – whereas the Form Wash automatically cleans your parts and prototypes. 

Jeff says the advantage of having a second Form Wash is that you can use Formlabs’ same theory of having a clean tank to do the final rinse. “I find it in my experience to be extremely useful to remove the supports for the second wash. The reason is that the supports block the fresh circulation of clean solvent from the parts. You will notice that for deep aspect bores and blind holes, if you do not remove the supports, they often times will not fully be cleaned of resin. After removing the supports and letting the parts bounce around in the basket during the last 10 minutes, they will always come out clean.”

Learn more FAQ by reading our related blog, “Everything You Need to Know About the Form 2 3D Printer.” If you’re interested in a free sample, then contact us at your earliest convenience. 

Also, follow me on LinkedIn for tips and tricks on how to use the Form 2 and other equipment and materials from Formlabs!