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Form 1 3d print
Form 1 + 3D Printer Review 2022
4.6
See Price
In a departure from the widely used FDM technology found in the majority of consumer 3D printers, Formlabs jumps off the bandwagon to offer a small form factor desktop SLA printer at a fraction of the usual cost.
On the back of a tremendously successful Kickstarter crowdfunding campaign that raised an eye-watering $3 million in the space of few months, the Form 1 and its advanced version, the Form 1 +, strives to bring the precision-oriented SLA technique to the masses.
How does it rival the standard FDM design and has Formlabs succeed in its mission to bring professional-grade quality free of the variable quality of other low-cost 3D printers to the average maker? Let’s find out.
| Printing Area | 125 mm x 125 mm x 165 mm |
| Layer Resolution | 25, 50, and 100 microns |
| Supported Filament | Liquid Plastic Resin |
| Technology | SLA |
| Software | PreForm |
Table of ContentsShow
Design and Features
Most striking is the orange acrylic cover that sits above a glossy grey base with soft contours, an efficient closed look, and a definite nod towards Formlab investing considerable time and money into generating a visually enticing device. The Form 1 + is well constructed with an intelligent design from the placement of the different components, the latched removable inverted build plate, and functional resin reservoir.
It’s easy to forget that the Form 1 + is supposed to sit alongside entry-level pre-assembled 3D printers due to how good it looks. It oozes precision and professionalism with an almost otherworldly attraction that drew us inexplicably to this machine. The total weight of 18 lbs is worth noting as it ensures the printer stands firmly on any surface with a robust set of low-profile feet.
As mentioned above it uses SLA tech, or inverted stereolithography, which involves a UV laser that cures or hardens a light-sensitive liquid plastic resin layer by layer into a solid object. The galvanometer-directed UV laser effectively draws on the surface of the liquid resin causing it to harden. Delving a little deeper the process centers on a process called photopolymerization, whereby molecules are fused and solidified when in contact with light to create polymers.
As you can see, this is miles away from the, at times, slapdash FDM technique, where plastic is melted then extruded layer by layer to create a printed model. Consequently, SLA usually carries with it a non-negligible price tag, if only for the equipment itself, but also for the actual liquid resin.
But the jump in price is also synonymous with a massive leap in quality as well. The results are incomparable to standard FDM tech, and if you were to put two identical models made via each of the technologies alongside one another, you’d be amazed by how much better the SLA printer performed.
The benefits don’t stop there, SLA is all but silent and long are the days of abrasive mechanical ear sores emanating from an FDM printer three rooms away. Equally, it is arguably safer due to only reaching temperatures ranging from 18 to 28 degrees centigrade compared to the standard 100 + degrees recorded during the operation of conventional 3D printers.
Now, to jump back to the hinged orange casing mentioned previously, it serves a fundamental purposes as it blocks outside light from infiltrating the closed chamber and spoiling the resin as well as looking pretty cool.
The Form 1 + packs a decent build area of 125 mm x 125 mm x 165 mm that is somewhat constrained by the incremental cost of SLA printing. The build volume took a hit to make the printer cost-effective. It’s smaller than most similarly priced FDM equivalents, but the upside is much better precision and detail.
At this point in our review, we would usually dive into extruder specifics, but as the Form 1 + doesn’t have one we jump to layer resolutions that range from an ultra-precise 25 to 100 microns alongside a minimum feature size of 300 microns (i.e., features of a model).
As for the resin itself, it is made of acrylate-based materials with an NPCA HMIS health safety rating of 2 (read moderately hazardous) and is produced exclusively by Formlabs and is, as expected, pretty expensive at around $150 for 500 mL, but much cheaper than the resin used for professional-grade machines. The standard resin is engineered for high-resolution details as well as strength and durability.
Formlabs offers a range of colors and finishes alongside castable and flexible resins. Third-party resins aren’t supported and unfortunately won’t work with the Form 1 +.
Formlabs believes in simplicity and no more so than in the controls on the Form 1 +, which is nothing more than a one-button control panel with monochromatic LCD.
Otherwise, connectivity is limited to USB-to-PC via Formlabs slicing/preparation software dubbed PreForm with inbuilt tools for orientation, rotation, scaling, duplication, support generation and placement, density and geometry options, monitoring and print time estimates, and STL/OBJ file support (pulled from any 3D CAD software) converted to FORM for the Form 1+ to read. PreForm is compatible with both Windows and MacOS.
PreForm is easy to use, intuitive, and definitely among the best proprietary forced usage software we’ve come across in our years of 3D printing.
Assembly
The Form 1 + comes amply protected in a package of suspended cardboard inserts holding the printer in place, edge protectors, and protective tape.
Unpacking involves removing the printer while being careful not to damage the packaging as it is designed for reuse when transporting the Form 1 +.
The package includes the Form 1 +, USB cable, power cord, power adapter, official documentation, quick start guide, safety guide, a 1L bottle of resin, and a Form Finishing Kit (setup guide, rinse bucket, rinse basket, tray, scraper, squeeze bottle, tweezers, absorbent pad, and disposable nitrile gloves).
The Form 1 + comes pre-assembled, and we mean genuinely, pre-assembled. No messing around fitting extruders, build plates, or filament spools. Due to the SLA tech, there’s no bed leveling or calibration either. It is functional straight out of the box.
Setup couldn’t be easier: remove the plastic protective layer from the resin tank paying attention not to smudge the bottom or top, plug in the power cord to the adapter and socket, connect the USB cable to the printer then PC, and finally switch on the Form 1 + via the button next to the display screen.
Print preparation is limited to filling the resin tank with liquid resin up to the marked line. Gloves are recommended which is a slight inconvenience, but otherwise, the process couldn’t be more straightforward.
Printing
For someone accustomed to FDM printers, the Form 1 + was a revelation. The quality of the prints can only be described as outstanding to the point that we’re genuinely dreading going back to FDM models.
The quality of the precision allows finite details on models to be abundantly apparent and not merely a blotched mesh of vaguely resembling filament that is so often the case with FDM. Every model we printed came out great with more detail than we are accustomed to in consumer/prosumer 3D prints.
The whole setup, slicing, and print initiation setup was also a pleasure and a world away from the overly complicated procedure usually associated with SLA style 3D printing. We did not once face any issues or failed prints at all.
The printer is also reasonably fast, and the revised Form 1 + is up to 50 times faster due to an improved UV laser and optics.
The finishing kit is also excellently designed with brackets to fit the detached build plate while you scrape off the model and an efficient rinse basket. The supports were easy enough to remove with a little force; a sure sign they were doing their job during the printing process.
The one real issue we had with the Form 1 +, but that comes with the SLA territory, was how meticulous we had to be in keeping the device clean. Any stray finger marks or blemishes on the resin tank meant cleaning it from top to bottom or risk ruining the curing process due to the precision of the optics, mirrors, and UV laser.
Support
Although Formlabs has technically stopped producing the Form 1 + in favor of the Form 2, they stay committed to providing expert after-sales support as well as a free one-year warranty, manning a repairs and servicing team, and providing educational resources from articles to videos by way of webinars and troubleshooting guides on its website.
Verdict
The Form 1 + takes the precision and quality of professional SLA printers, miniaturizes it, simplifies the printing process, and produces high-resolution prints with a nearly perfect finish.
If you want something different to the standard FDM design, then the Form 1 + offers the ideal all-in-one package to get your feet wet.
Although the ongoing cost of resupplying the resin tank can prove costly overtime, the Form 1 + uses resin sparingly, and we were surprised by how many models we were able to pump out with the stock 1L bottle. The long term cost is worth keeping in mind, but not a deal breaker in our book.
The cost of the resin means you won’t use it to create and experiment with test models. We see it more as finishing tool for low tolerance prototyping and models for casting.
The price tag hovers around the $3000 mark so this printer isn’t necessarily within the realm of the novice or first-time buyer, but veterans on the lookout for a new addition to their collection will find a lot of joy in the Form 1 +.
Resin Library and 3D Printing Materials
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General Purpose
Outstanding performance. Excellent detail.
Custom-formulated to deliver the highest-quality output, our Standard Resins capture astonishing detail without sacrificing strength.
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Engineering Resins
Functional prototyping materials.
Our library of versatile, reliable Engineering Resins is formulated to help you reduce costs, iterate faster, and bring better experiences to market.
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Dental Resins
Professional materials for digital dentistry.
Formlabs Dental Resins enable high precision, low-cost digital production of a range of dental products in-house, including surgical guides, orthodontic models, retainers, and aligners.
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Jewelry Resins
High-detail materials for jewelry design and clean investment casting.
Prototype impressive concept models and manufacture distinctive pieces with sharp resolution and the best surface finish on the market, from idea to fitting to casting.
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Medical Resins
3D Printing Materials for Healthcare.
Access a library of over 20 materials available on one powerful desktop 3D printer, the Form 3B+. Our technology has been validated in FDA-cleared workflows and we develop and manufacture our own biocompatible materials in an ISO 13485 certified facility.
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Production-Ready Materials for the Fuse 1 generation printers.
Balancing strength and detail, our powders for selective laser sintering (SLS) are highly capable materials for both functional prototyping and end-use production of complex assemblies and durable parts with high environmental stability.
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Handling & Safety
Handling & Safety
Resin should be handled with care. Proper handling will ensure safe printing and efficient use. Our resins have been designed to be similar or safer to handle as other household chemicals or adhesives. Formlabs materials do not contain volatile solvents so special ventilation is not required. Skin contact should be avoided.
The Safety Data Sheets (SDS) are up to date for every resin product and follow the latest government guidelines. Always consult the SDS as the primary source of information to understand safety and handling of Formlabs materials.
For more information about handling resin, learn more tips for resin maintenance in our Help Center.
Technical Data
Technical Data
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3D printing mold making
Desktop 3D printing molding allows engineers and designers to get more functionality out of a 3D printer beyond prototyping. Molding opens up a world of production materials and provides the opportunity to produce small batches and sample test molds before using expensive
tools.
This booklet covers the following three mold making strategies: injection molding, high temperature molding and injection molded elastomers. Typically, molds are made from Formlabs clear resin, which is preferred for its transparency, although any standard resin can be used, and high temperature resin is ideal for processes with high temperature requirements. It should be noted that these processes are best suited for stereolithographic 3D printing (SLA) because the printed parts are isotropic and waterproof.
Prototyping and small-scale production with 3D printing tools
| Process | Equipment | Run time | Material cost (for example: 300 ml/cm3) |
| Do-it-yourself mold making and parts making | Mold 2 and injection molding machine | 5 to 24 hours (form print time) | Approximately $50 for High Temperature Resin |
| Outsourced SLA Form | injection molding machine | 3-5 days | Approximately $700 for back office printing on industrial SLAs |
| Outsourced metal mold | injection molding machine | 1-2 weeks | Approximately US$6,400 for office desk, aluminum finish |
| Outsourced mold Creation and production | no - full outsourcing | 1-3 weeks | $4,000 to $15,000 depending on volume and materials |
Silicone molding and some desktop molds are available using Formlabs Standard Resins High Temp, which has the highest HDT at 0.
45 MPa for any 3D printed materials currently on the market and allows print parts that can be used for high temperature forming such as thermoforming and injection molding of materials with higher melt temperatures
Injection molding
High-resolution SLA 3D printing on the Form 2 can be used to quickly prototype inexpensive injection molds that can be used to make real parts from a wide variety of
thermoplastic materials. Injection molds can be used to test mold designs prior to metal tooling or to produce low-volume parts
3D Printed Injection Molding covers injection molding using Formlabs clear resin printed molds. Following the release of Formlabs High Temperature Resin, designed to achieve higher heat resistance and stiffness, the booklet has been updated to describe the benefits of High Temperature Resin plates that are less likely to break due to thermal shock or temperature-related deformation
USB Device Enclosure Mold, 3D Printed on Form 2 High Temperature Resin
This mold contains a core, a cavity, and two "gates" leading to the two halves of the enclosure.
High temperature resin molds can be used to mold a wide range of thermoplastics without thermal stress or temperature-related deformation
Formlabs High Temperature Resin can be used to injection mold a wide range of plastics.
3D printed mold tools reproduce the exact quality of the SLA print finish on the Form 2. Forms can be printed at 100 microns for faster prototyping or the recommended 50 microns for fine detail and smoothness
electronics molded in HDPE with a High Temp tool.
This shape of the USB case has been adjusted over three iterations to remove cavities, entrapped air, and partial shrinkage. Total cost of materials for prototyping this high temperature resin mold tool: $25
Thermoforms
Form 2 3D printed thermoformed dies are a fast and efficient way to create high quality vacuum formed parts for low volume production. Printed thermoformed dies can be used to make packaging prototypes, clean orthodontic retainers, and food-safe molds for chocolate confectionery.
Thermoforming dies experience less pressure than injection molds, but still reach high surface temperatures.
High temperature polymer resists deformation and surface degradation from the combined heat and pressure of thermoforming for most plastics. Standard resins may also be suitable for thermoforming with some low temperature plastics such as vinyl.
APPLICATION EXAMPLE
Formech thermoformed prototype packaging.
Thermoforming a thin sheet of polycarbonate over a high temperature polymer matrix produces a transparent detail by matching the geometry and detail of the matrix. Thermoformed packaging can be easily prototyped and incorporated into the design process along with 3D printed product prototypes, and all this is achievable on the Form 2. The printed matrix was used without additional processing and the need for UV curing. Texture is recommended in thermoforming design to prevent air trapping under the sheet - layer lines on the printed thermoforming die can be helpful in this regard.
TEMPERATURE CONTROL
High Temperature Polymer Cycle Thermoforming
The surface temperature of the die reaches 130°C. The high temperature resin is highly resistant to deflection, whereas with standard resins you must allow the print matrix to cool between cycles, otherwise warping and degradation may occur.
If temperature rise becomes a limiting factor in molding efficiency, cooling channels are an effective way to remove heat from the print. When used in conjunction with an automated thermoforming machine, the water-cooled die can produce more parts with shorter cycle times.
Conformal water channels visible in the thermoforming high temperature die.
Thermoforming die surface temperature
Conformal cooling channels are easy to implement when designing for SLA 3D printing and print successfully without any internal supports to interfere with flow. After printing, the channels are flushed with uncured resin using isopropyl alcohol.
The mold is connected to a pump and a source of cold water.
Integrated water cooling as a strategy can also be applied to standard and rigid polymer parts to reduce heat dissipation when used in higher temperature environments.
Elastomer casting
Precision molds for most flexible elastomers such as silicone and urethane rubber can be printed on the Form 2 using standard resin. The transparency of Clear Resin allows the material to be observed during the pouring or injection process. Flexible materials can be easily removed from rigid SLA printing plates, and applications from model production to functional molding can be obtained. Silicone molding can also be used to quickly replicate master prints, greatly reducing production time when multiple rigid parts and objects are needed.
APPLICATION EXAMPLE
Forms printed on Form 2 are used to create composite parts with advanced built-in features. Assembly subcomponents such as electronic, metal and SLA printed elements can be embedded and sealed in soft surface molds.
RightHand Robotics used the Form 2 to create the production blocks of their robotic gripper using urethane molding. The forms were printed in clear resin, with black resin inserts forming the internal structure.
The Form 2 printer allowed RightHand Robotics to move from prototypes to small-scale production without the need for expensive tooling. The rapid transition from original printed prototypes to production materials that have longer flex cycle life was done with 3D printed plates on the same Form 2 hardware they used for initial prototyping.
The first layer applied from RightHand Robotics' multi-stage process includes urethane compounds that can withstand multiple flex cycles while still providing the high elasticity needed to securely return the gripper to its open state.
The outer layer provides improved tactile grip and control, as well as sealing the sensor electronics with softer, lower durometer rubber.
SLA 3D printed parts can also be encapsulated inside molds to provide a rigid structure for flexible materials.
The overlay can be mechanically bonded to the insert by adding holes, recesses, and columns to the printed parts, which enhances assembly and reduces the need for chemical adhesive.
Conclusion
Form 2 molding is a powerful strategy for the production of parts in small batches, as well as production from commonly used plastic and elastomer materials. 3D printing tools allow engineers and designers to easily prototype parts that look and function exactly like the final product, with geometries and material configurations that are quite complex, using 3D printing, such as in the case of encapsulated electronics and thin packaging. For high temperature forming, high temperature polymer offers superior thermal properties at a lower cost and with shorter lead times than process outsourcing
Molds on a 3D printer. Creation of molds on a 3D printer
Molds on a 3D printer Formlabs
A mold is a metal device of complex geometry for molding plastic products.
The idea of creating a mold on a 3D printer has long been on the surface. The search for cheaper and faster ways to produce is drawing attention to 3D printing. Rapidly developing new technologies, which only yesterday created rather rough mock-ups and prototypes, are already today ready to offer very accurate and functionally working parts and fixtures.
The American company Formlabs, which has created a fully automated life cycle of industrial photopolymer 3D printing, focuses on 3D printing exclusively with its resins. Thus, in response to ever-increasing demand, Formlabs is developing new formulas that are also used in small-scale production. A range of Formlabs engineering resins easily handle the rigors of the injection molding process. Formlabs 3D printed molds made from tough, durable resins are great for low-volume, breakage-free, leak-free production.
Compared to traditional metal mold processing, the availability of Formlabs 3D printed molds results in a faster return on investment and helps customers bring products to market quickly.
Injection molding in 3D printed molds
These molds are used for injection molding. Therefore, they must withstand clamping pressure, injection pressure and injection temperature. In addition, withstand any coolants or mold lubricants that may be used. The form's stability against these factors ensures that it can be used repeatedly and for a long time. And at the same time, it must consistently produce parts identical to the original design.
Formlabs 3D printers have been tested on desktop and industrial injection molding machines under a wide range of conditions. These low volume molds can handle hundreds to thousands of injections depending on several factors:
- part design;
- mold and injection molding materials;
- molding parameters;
- coolants and lubricants for demoulding.
Resins for 3D Printing Molds
Formlabs offers a range of materials that can replace aluminum molds for small batch production.
- Rigid 10K Resin combines the qualities of strength, stiffness and thermal resistance. That is why, it is an ideal material for injection molds. The increased strength ensures that the Rigid 10K mold can withstand clamping and injection pressure without breaking. And the high rigidity allows the mold to hold its shape under this pressure and produce precise parts.
- High Temp Resin is a lower cost alternative that can withstand temperatures up to 238°C. Its use can be tolerated if the clamping and injection pressures are not too high. Where Rigid 10K Resin cannot meet the required injection temperatures.
- If dimensional accuracy of forming parts is less important, choose Gray Pro Resin . It operates at lower pressures and temperatures and is more flexible at the same time. The shape of this material is potentially more durable, because. it is a more flexible material that bends before breaking. At the same time, this potentially reduces accuracy over time as the form is used.
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