Resin printers use liquid photopolymers that are cured layer by layer through targeted exposure. They enable particularly fine details, smooth surfaces and high dimensional accuracy. Modern systems increasingly rely on intelligent control, automated resin processes and optimised light sources to further improve print quality and reduce operating effort.
The Form 4 from formlabs uses masked stereolithography (MSLA) in combination with a low-force display printing system, reducing stress during lift-off and enabling more precise and faster production. Its production volume is 20 × 12.5 × 21 cm (5.25 litres), in which parts with a maximum length of up to 27.3 cm can be produced. The layer thickness can be flexibly adjusted between 25 and 200 µm. During printing, the Form 4 achieves a resolution of 50 µm in the XY plane, which is supported by preset edge smoothing. With a maximum printing speed of 100 mm per hour, which averages around 40 mm per hour, the Form 4 is one of the faster MSLA printers. The dimensional accuracy in the XY plane is a maximum of ±0.3% for larger structures up to 150 mm and a Z-axis force sensor automatically adjusts the print speed and quality to the respective geometry and the selected material. Overall, 99.7 % of the surfaces deviate from the CAD model by a maximum of 100 µm during printing. The illumination unit of the Form 4 consists of 60 LEDs with a uniform wavelength of 405 nm and an array of plano-convex lenses that ensure uniform exposure. The printer also has a flexible resin tank which, in conjunction with the low-force system, leads to particularly clean removal processes. In addition, automatic resin handling speeds up the workflow, while conduction heating, which is controlled by an infrared temperature sensor, keeps the resin viscosity stable. Automatically generated support structures can be easily removed after printing, making post-processing easier.
For easy operation, the device has an interactive 7-inch touchscreen that provides access to settings, status displays and notifications. An integrated camera allows users to remotely monitor and view the print progress and time-lapse recordings on completion. The Form 4 thus combines high precision, robust process automation and a sophisticated operating concept to create a high-performance resin printing system.
