Formlabs Form 4 Printer Training Guide

Welcome to Resin 3D Printing at MakeIt Labs!

This guide will walk you through everything you need to know to safely and successfully use the Formlabs Form 4 printer at MakeIt Labs. It consists of:

• A basic overview of Resin printing (including diagrams and links to FormLabs videos)

• Rules related to using the Form 4 at MakeIt Labs, including costs, reasonable use/“no print farms” and others

• Steps to complete before quick in-person final authorization

If you have any difficulty going through this training, please reach out to the #resource-3dprinting Slack channel or DM the 3D printing resource manager (Bill Schongar) directly. We’d much rather you ask questions than accidentally cause an issue!

1. Introduction to Resin Printing

How Resin Printing Works

Resin 3D printing, also known as stereolithography (SLA), works differently from traditional filament-based (FDM) printing. Instead of extruding melted plastic, resin printers use light to cure liquid photopolymer resin layer by layer.

The Basic Process:

1. Liquid Resin Tank: The build platform starts at the top of a tank filled with liquid resin

2. Light Projection: A light source (laser or projector) shines onto the bottom of the resin tank, curing (hardening) the resin in specific patterns

3. Layer by Layer: After each layer is cured, the build platform raises slightly, and a fresh layer of liquid resin flows underneath

4. Build Completion: This process repeats until the entire object is built upside-down from the build platform

Key Advantages of Resin Printing:

• Extremely high resolution and smooth surface finish

• Ability to print fine details and intricate geometries

• Excellent for prototypes, miniatures, jewelry, and dental applications

Important Considerations:

• Resin is a chemical that requires careful handling

• Parts must be washed and post-cured after printing

• Proper PPE (gloves, safety glasses) is required when handling resin

How SLA printing works - Video (9m17s)

For a visual introduction to how SLA printing works, watch this Formlabs overview: SLA Printing Explained  (Formlabs Official Channel)

2. Using PreForm Software

PreForm is Formlabs' free slicing software that prepares your 3D models for printing. It handles model orientation, support generation, and file export to the printer.

Getting Started with PreForm

Download and Installation:

• Download PreForm from formlabs.com/software

• Available for Windows and macOS

• Create a free Formlabs account with your Makeitlabs email address (<firstname>.<lastname>@makeitlabs.com)

  1. We will not authorize any non-Makeitlabs email addresses for printer use.

Key Workflow Steps

1. Import Your Model: Drag and drop STL or OBJ files into PreForm

2. Automatic Orientation: PreForm suggests optimal orientation for print success

3. Select Material and Layer Height: Choose your resin type and desired resolution

4. Generate Supports: Automatically creates support structures (can be edited manually)

5. Estimate Print Time and Material: Review costs before printing

6. Export to Printer: Send directly via USB, WiFi, or export to USB drive

Important PreForm Concepts

Supports: Temporary structures that hold your print during fabrication. These must be removed after printing. PreForm automatically generates these, but you can:

• Adjust support density

• Add or remove individual support points

• Change support touchpoint size

Orientation: How your model is positioned on the build platform matters significantly:

• Minimize cross-sectional area to reduce peel forces

• Avoid large flat surfaces parallel to the build platform

• Consider drainage holes for hollowed prints

Layer Height:

• Thinner layers = higher detail but longer print time

• Common settings: 50 microns (high detail), 100 microns (standard)

Review Preform Documentation page and videos:

Navigate to the Preform software page for the latest overviews and videos, as well as links to other topics. At a minimum, complete any of the videos on the main page (about 10 minutes in total currently)

3. Introduction to the Formlabs Form 4

The Form 4 is Formlabs' latest desktop SLA 3D printer, featuring improved speed, reliability, and print quality.

Key Features

• Low Force Display (LFD) Technology: Uses an LCD screen to cure entire layers at once, significantly faster than laser-based systems

• Build Volume: 20 × 12.5 × 21 cm (7.9 × 4.9 × 8.3 in)

• Automatic Resin System: Integrated resin cartridge and tank system for easy material management

• Heated Build Platform: Improves print success and material compatibility

• Material Versatility: Compatible with Formlabs' extensive material library

Machine Components

Front of Printer:

• Build Platform: Where your print attaches and builds

• Resin Tank: Contains the liquid resin during printing

• Touchscreen Interface: For printer control and status monitoring

Side/Back of Printer:

• Resin Cartridge Slot: Houses the automated resin delivery system

• Power Connection: Standard power cable

• Ventilation: Built-in filtration system (ensure proper ventilation in your space)

Basic printer use overview video (7m22s)

This video provides a view of the end-to-end process for using the printer, including a brief glimpse at the software

1. Form 4 workflow from Cimquest 

Note: Visit the Formlabs Support Center for the latest information and tutorials specific to the Form 4.

4. Makerspace-Specific Rules and Procedures

The Form 4 is an expensive piece of equipment, and we only have 1 of them currently. So we need your help to be sure you help take good care of it and follow all procedures.

We’ll cover 4 main topics here:

1. How Consumables work at MakeIt Labs 

2. Safety when printing and post-processing

3. No monopolizing the printer (also the “no print farm” rule)

4. What to do after reading this guide

How Consumables work at MakeIt Labs

There are three types of consumables for the Form 4:

1. Resin (Formlabs branded only. No 3rd party resins)

2. Resin Tank

3. Resin Tank Wiper

It’s important to note that the Form 4 is currently set up only to use FormLabs resins. We do have other Resin printers which can use any 3rd party resin, so it is always possible to be trained to use those. However, since the Form 4 provides ease-of-use, and the branded resins ensure high success rates, we have focused our training resources on the Form 4 for now.

We will typically have 1-2 basic resins on-hand, each of which have a specific tank and wiper they are to be used with. This is for two reasons:

• You cannot refill a resin bottle. The only way to store “leftover” resin is in a tank with the lid out of the light. So the tank and the resin go together.

• We can’t stock all the types of resins people may want. It gets EXPENSIVE.

If you use one of the basic resins, your existing card on file for Makeit labs monthly payments will get charged for the amount used. So pay careful attention to how much each print costs when looking at Preform.

If you choose to “Bring Your Own” Formlabs resin, we do not have spare tanks and wipers, so it will ALSO require you bring your own tank and your own wiper. Do not, for any reason, dump out resin from another tank to use with your own resin. You will be banned from using the Form 4 and charged for the wasted material if you do. You have been warned.

Safety when printing and post-processing

Resins are hazardous. So remember:

• Turn on the ventilation fan (switch on the table) when printing or post processing

• Wear gloves when you may potentially touch resin or isopropyl alcohol (cleaning solution for prints)

If you feel a headache or other symptoms when working with resin, and the ventilation is on, set things down and leave the room immediately, closing the door behind you. Some people have resin sensitivities, and there is a small possibility you may be one of them. So if something feels amiss, it is better to leave things exactly as they are and ask for help closing up bottles and tanks while you get fresh air.

If you spill resin, be sure to clean it up. If it is a small amount, such as a teaspoon or less, wipe with a paper towel then UV cure the paper towel in the cure oven for 60 seconds before throwing it away If it is a large spill, ask for help on the #help channel on Slack.

All UV cured resin waste is safe to dispose of in the regular trash. This includes support material, utensils with resin on them and so forth. IF you have any questions on disposal of anything, feel free to ask on the #resource-3dprinting channel.

The “no print farms” rule

3D printers at Makeit labs may not be used for 3d printing businesses. This includes any activity where you are regularly reselling 3d prints. 3d printers may also not be monopolized, running multiple long print jobs in a row.

How do we interpret this?

• You want to print something for a friend as a gift.. Great, go for it.

• You want to print an entire collection of minis for a friend as a present. Batch this into one job at a time, and space the jobs out every other day or longer.

• A friend or a “friend of a friend” wants something and will reimburse you. Sure, but don’t make a habit of it.

• You let people know you have access to a 3D printer and you can make things if they pay you. Nope, don’t do this.

• You advertise 3d printing services or 3d printed products and use Makeit labs printers to create them on a regular basis. Nope, definitely do not do this.

If you run into a situation you’re not sure of, for example you’re trying to create a batch of prototypes for a business you’re starting on your own, talk to the 3d Printing Resource manager directly. Our goal is not to keep you from being successful, it is to make sure the wear&tear&availability of the printers is fair to everyone.

What to do after reading this guide

Have you:

• Watched all the videos?

• Read the Preform software page?

• Created your Formlabs account using your Makieitlabs email?

Then your next step is to schedule a quick signoff for using the machine. Our goal is to make these take under 10 minutes, and run one every other week as well as informally when time permits.

To schedule a signoff:

1. Send an email to “3dprinting@makeitlabs.com” with the following title: “Form 4 Authorization Request for (your name)”

2. We’ll check that your Formlabs account has been created, and then get back to you with the next available time options.

   1. We’re aiming to potentially have one every Tuesday during Member Nights, but still working out schedules

At the signoff we’ll simply be:

1. Walking through loading and unloading the printer

2. Pointing out safety items

3. Adding you to the authorized printer group in Preform

Our goal is to enable people who have completed the training to be able to serve as guides for others as well - this drastically reduces the time to get people started in printing, and helps us as an organization to support one another.

Questions?

If you have any questions, please reach out on the #resource-3dprinting channel on Slack and we’ll do what we can to help you get going!