Formlabs entered the 3D printing market with a huge splash in 2013 with the Form 1 stereolithography (SLA) 3D printer, one of the most funded crowdfunding projects ever to hit Kickstarter. Since then, the company has grown significantly, expanding into the international market, launching its flagship machine, the Form 2, with a developing line of functional resins for 3D printing.
The Form 2 is the latest version of the flagship 3D printer from Formlabs. The desktop-sized SLA system features a build volume of 5.7 in × 5.7 in × 6.9 in (145 mm × 145 mm × 175 mm), which is 40 percent larger than the previous Form 1+. Featuring a 250-MW laser (50 percent stronger than that of the Form 1+) with a spot diameter of 140 microns, the Form 2 has improved resolution over its predecessor and is capable of layer thicknesses as fine as 25 microns (.001 in). A price of $3,499 makes the Form 2 competitive with more expensive industrial SLA machines.
Other features include an automated resin system, with which new material cartridges automatically fill the resin tank while an object is printing. The Form 2 also improves on the Form 1+ through the addition of a sliding peel mechanism with a wiper and heated resin tank, enabling the fabrication of larger solid parts with fine details.
A built-in touchscreen and Wi-Fi connectivity make the Form 2 office and workshop ready, allowing users to manage the printer remotely. Formlabs' PreForm software, included with the printer, has auto-orientation and smart support generation built in.
Since initially spun out of MIT, Formlabs has developed not only a highly regarded 3D printer, but also its own line of photopolymer resins. These include Formlabs' standard clear, white, grey and black formulations, as well as functional resins, which range from castable, flexible and tough materials to the biocompatible Dental SG resin.
How the Form 2 Works
The Form 2 is an SLA 3D printer, meaning that it focuses a laser onto photosensitive resin in order to fabricate parts. In the case of the Form 2, this laser is a 250-mW, 40-nm violet laser, which is directed at a series of mirrors mounted to a custom-designed galvanometer system that bounces the UV light onto the resin. The resin is located in a heated tank sitting above an optical window. As the light hits the resin, it is instantly hardened.The print bed is then raised up in increments, allowing the next layer of resin to be cured. With each layer, the optical window slides from side to side, allowing for a clean separation of the part from the resin tray within the tank. Next, a wiper wipes the area, ensuring an even spread of material for the subsequent layer.
These features, not included in the Form 1+, allow for a greater print success rate and for the printing of larger parts. The new side-peeling mechanism prevents prints from getting stuck to the resin tray, while the wiper prevents excess material from blocking the laser as it attempts to harden the proceeding layers.
Unlike extrusion-based desktop technology, which produces less detailed objects at relatively slow speeds, SLA is known for its high resolution, smooth surface finish and relatively quick printing pace. The use of a laser makes SLA ideal for very fine features, though it may not be quite as fast as digital light processing technologies.The Form 2 in Action
In developing a line of “Smart Nursery” products, a company called Rest Devices has relied on the Form 2 3D printer to prototype products and create jigs and fixtures for its manufacturing operations. Specifically, Rest Devices leveraged the Form 2 for designing the Mimo Smart Baby Monitor, meant to provide parents with data about their infant’s sleeping patterns.The Mimo device consists of a plastic turtle, which houses sensors for monitoring a baby's heart rate and sleeping position. Rest Devices utilized the technology to create jigs for pressing magnets into the base of the turtle. The company also used the printer to fabricate a rig for programming circuit boards with a camera and computer vision to recognize the ID on each Mimo.
Rest Devices is a small operation, which designs and tests its products in-house before working with a contract manufacturer. Having a desktop 3D printer in-house speeds up production, while reducing cost. As Rest Devices engineer Silas Hughes elaborated, “3D printing [is] an integral part to how the products developed, how we think about developing and how we manufacture.” He added, “In our manufacturing process, if we weren't using 3D printing, simply put, it would take longer and it would cost more money.”
Thomas Lipoma, founder of Rest Devices, spoke to the qualities of the Form 2. “We are definitely a big fan of Formlabs and 3D printing in general. We have used every type of commercial 3D printing available and one of the big advantages [of the Form 2] is the level of quality for the price,” Lipoma said. “With the Form 2 we can get an extremely high quality, high resolution print on a small desktop platform that is very affordable. In addition, variety of print material is unparalleled in terms of the different material properties we can achieve.”Lipoma added, “I would say that, while the Form 2 gives extremely high quality prints, the print time along with the final cleaning/curing can take a bit of time and energy.”
Manufacturer: Formlabs
Model: Form 2
Material: Standard clear, white, grey and black resins; functional castable, flexible and tough resins; biocompatible Dental SG resin
Build Envelope: 145 mm × 145 mm × 175 mm (5.7 in × 5.7 in × 6.9 in)
Layer Thickness: 25µ (.001 in)
Printer Dimensions: 342.9 mm x 330.2 mm x 520.7 mm (13.5 in × 13 in × 20.5 in)
Printer Weight: 13 kg (28.5 lbs)
Recommended Uses: Rapid prototyping; 3D printing castable items, such as jewelry, electronic components and dental crowns; producing jigs and fixtures
Machine Price: USD$3,499
Who Should Use the Form 2:
The Form 2 is an affordable high-resolution professional desktop 3D printer, making it ideal for any business looking to speed up production through in-house prototyping. Businesses can leverage the Form 2 for short run manufacturing of custom goods. Due to the Form 2's precision, Dental labs and jewelers can 3D print castable models for jewelry and crowns. Readers can request a free sample part printed on a Form 2 from Formlabs here.
Why You Wouldn't You Use the Form 2:
Those looking for a printer capable of mass production and fabricating large-scale objects may want to look for a bigger machine.Formlabs has sponsored this post. It had no editorial input. All opinions are mine. —Michael Molitch-Hou