Advanced 3D Printing Techniques

Posted by FIT THAI on June 5, 2026

3D printing is a powerful tool, and Formlabs resin 3D printers make it easy to start printing parts.

By incorporating advanced techniques into your 3D printing process, you can expand the scope of what can be created even further, from surface finishing and assembly to manufacturing and processing parts. Advanced 3D printing techniques open up opportunities to efficiently create 3D printed molds, electroplating, various surface textures, parts for assembly or connection, prints larger than the printer in use, and much more.

CAD and 3D Modeling

Snap-Fit Joints

This plastic electronics enclosure was 3D printed with a Formlabs resin 3D printer.

There are various types of snap-fit part designs that allow plastic parts to be joined without screws or glue. Snap-fits are often used in custom enclosure designs, as well as for securely connecting 3D printed parts.

For more information, please refer to our step-by-step guide on designing and 3D printing snap-fit enclosures.

Large Models

When considering the capabilities of a compact desktop 3D printer, don't just look at the build volume.

You can create large objects by dividing the object into several sub-parts and designing pins and slots to aid in correctly assembling the parts, or by using chemical fastening for non-load-bearing or non-structural applications.

With these methods, small 3D printers can effectively produce objects larger than their build volume.

The precision and accuracy of Form Series 3D printers allow Harlequin Design to easily assemble small parts into life-size models.

For more information, refer to the guide on assembling large parts or read the case study of Harlequin Design, a visual merchandising company that assembles multiple large 3D printed parts to create works for many leading global brands.

Lattice Structures

Two New Balance products utilize lattice structures produced with 3D printing technology to help absorb shock and return energy efficiently, using less material and weighing less than parts produced with traditional manufacturing methods.

Lattice structures are a common feature in 3D printed parts because they offer an easy and cost-effective way to create many negative features such as holes, slots, and through-holes, with almost no limitations on size or angle of the structure.

These negative features reduce the amount of material required for production, shorten printing times, and can maintain or even enhance the strength and performance of the part.

For flexible or semi-rigid materials, lattice structures also help increase the ability to support and distribute compressive, tensile, or impact forces from multiple directions and intensities, allowing the part to be flexible where needed and strong enough to resist compression or torsion in other areas.

For more information, you can study the New Balance case study for an example of applying 3D printed lattice structures in actual products.

Direct Translation

Also known as Compliant Mechanisms, Flexure mechanisms include both living hinges and other flexible mechanisms that generate force and movement through the deformation of an elastic body.

Utilizing the properties of these compliant mechanisms allows for the creation of mechanisms with high precision and low hysteresis, or minimal error from repeated responses, resulting in more consistent and accurate movement and position control.

Simply put, instead of using hinges, bearings, or multiple moving parts, the mechanism relies on the bending or flexibility of the material itself to create movement, which helps reduce the number of parts, minimize wear, and increase operational accuracy.

This compliant mechanism was printed with Tough 1500 Resin.

To evaluate the performance of 3D printed compliant mechanisms yourself, you can request a free sample part printed with PU Rigid 650 Resin to test and examine its properties firsthand.

This material is suitable for producing parts that require strength, precision, and consistent mechanical response, which are crucial properties for designing compliant mechanisms and self-moving engineering components.

Gaskets

Custom Gaskets from Dorman Products, produced with 3D printing from Silicone 40A Resin.

Many industries require a large number of custom or low-volume waterproof and gas-tight parts, such as marine research, underwater robotics, sustainable technology engineering, oil and gas industries, and defense.

3D printing can help create watertight enclosures by designing O-ring grooves into the part and installing O-rings to create a leak-proof seal.

To learn more about 3D printing for waterproofing, please refer to the White Paper, which covers topics such as:

How to choose the appropriate O-ring for the application.
Guidelines for designing waterproof parts.
Pressure testing results of 3D printed waterproof enclosures.

Assembly

Threads and Inserts

Knowing how to create strong and functional assemblies from 3D printed parts saves engineers time and cost. Screws, bolts, and threaded parts are commonly used methods for assembling and aligning mechanical components, as well as for transmitting motion within various mechanisms.

Screws can be fastened to 3D printed parts in several ways, such as using inserts, tapping threads, or printing threads directly as part of the component.

To learn more, read articles on creating threads with 3D printing and installing threaded inserts in 3D printed parts to choose the appropriate method for each application.

Resin Adhesive

Formlabs resin can act as an adhesive when exposed to UV light. A syringe or similar device can be used to apply resin to the desired bonding area. Then, a 405 nm (nanometer) laser or laser pen can be shined onto the resin. Within seconds, holes can be filled, cracks repaired, or parts joined together.

However, due to the specific properties of Formlabs resin, this technique requires a 405 nm wavelength laser or laser pen to function effectively.

For more information on using resin as an adhesive, please refer to the Formlabs forum.

Manufacturing Techniques

Jigs and Fixtures

Create manufacturing aids with 3D printing, such as jigs, fixtures, alignment pins, and caps.

Jigs and fixtures are used to simplify and increase the precision and consistency of manufacturing and assembly processes, reduce cycle times, and improve worker safety.

Typically, manufacturers create these tools from metal using machining processes, either in-house or by outsourcing. However, in many cases, metal is not always necessary. Formlabs resins can be used as a substitute for metal fixtures in applications such as:

Automated machining systems
Electronics assembly lines
Metal foundries
Other factories and production lines

For more information, read the guide on replacing machined jigs and fixtures with 3D printed parts to learn how to reduce costs, shorten production times, and increase flexibility in designing manufacturing aids.

Sheet Metal Forming

Form complex metal parts from sheet metal using 3D printed plastic molds.

Metal parts are widely used in various products, from electrical appliances and construction components to car body panels, due to their strength, rigidity, and long-term durability.

Sheet metal forming processes require dies, which are typically machined from metal and, in many cases, outsourced to external manufacturers, leading to high costs and long lead times.

With Formlabs resin 3D printers, users can produce plastic molds for sheet metal forming in-house, significantly reducing production time, mold creation costs, and rapidly accelerating testing or design adjustments before entering actual production.

Molding and Casting

Can work with a wide range of materials, including silicone and thermoplastics, by injecting or casting materials into 3D printed molds, whether they are:

Two-part injection molds
Overmolds
Compression molds
Eggshell molds

These methods can be used in various ways, such as creating product prototypes, producing small quantities of test samples for beta customers, or manufacturing custom products for actual use.

Using 3D printed molds reduces development time and cost compared to traditional metal mold manufacturing. It also allows for rapid design iteration and testing of new concepts before mass production.

Unilever and Serioplast use 3D printed molds for rapid stretch blow molding to develop and test new bottle designs quickly and at low cost.

Both companies have shared the key benefits and practical application examples of this technology in case studies and webinars.

To learn more about producing silicone parts with 3D printed molds, you can study the user guide or download the White Paper that describes the use of molds to produce medical devices made from silicone, covering design guidelines, production processes, and considerations for practical application in detail.

Insert Injection Molding

Insert molding is another form of injection molding where existing parts are placed inside a mold, and then plastic is injected to encapsulate or bond with those parts, forming a single component.

Insert molding is often used to add a plastic layer to metal parts, for example, creating a plastic handle for a metal screwdriver to improve usability and grip.

Additionally, this process can be used to produce:

Insulated pipes
Insulated wires and cables
Products requiring the combination of multiple material types
Plastic parts with embedded electronic circuits or devices

Insert molding reduces assembly steps, enhances part strength, and allows for the efficient integration of various materials or components into a single product.

3D printed molds can be used for insert molding processes.

To learn more about insert molding, including guidelines for selecting the appropriate application for each product type, you can read the guide that describes the principles, processes, and design considerations.

Additionally, you can download the White Paper to study 3 real-world case studies demonstrating the effective application of 3D printing technology with insert molding in product development and manufacturing.

Thermoforming

Use 3D printed parts as molds for forming thermoplastic sheets under heat and pressure.

3D printed thermoforming molds can be used with both desktop machines and industrial equipment, allowing for the rapid and cost-effective production of functional prototypes, pilot production parts, or custom, low-volume production parts.

From orthodontics to the packaging industry, thermoforming is a highly flexible manufacturing process that can be applied in various industries.

To learn more, you can explore guides, resources, and various case studies on thermoforming, or download the White Paper to delve into the thermoforming process and its application with 3D printing technology in detail.

Stamping

Print parts with Flexible Resin to create custom stamps.

Use Formlabs Flexible 80A Resin to produce flexible and compressible stamps suitable for applying ink to various surfaces.

You can refer to the user guide to learn how to create custom stamps in 7 easy steps, from design to practical application.

Translucent Lithophanes

A lithophane is a three-dimensional image that changes with the intensity and characteristics of light passing through it.

Brighter areas of the image are very thin, allowing more light to pass through, while thicker areas appear darker as less light penetrates them.

By adjusting the thickness of the part to control the amount of light passing through each point, images with detailed light and shadow can be created using stereolithography (SLA) 3D printing technology.

The result is a three-dimensional object that, when lit from behind, reveals a dimensional and photographic-like image. This is a popular application of 3D printing for art, decorations, and personalized gifts.

Hold the lithophane up to the light or create a lamp with LED backlighting to reveal the image clearly.

When light passes through, the lithophane reveals image details through variations in thickness, creating a dimensional image with light and shadow levels similar to a photograph.

To create your own lithophane, you can explore step-by-step guides on free lithophane generators or learn advanced techniques and tools from recommended articles to help you design and create higher-quality pieces.

Surface Finishing

Dyeing

Dyeing is one method to add color to 3D printed parts, including anatomical models used for diagnosis and education.

Parts can be colored either by printing with pre-colored resin or by dyeing after printing.

Although SLA 3D printing technology is renowned for its high precision and detail, it offers fewer options for direct multi-color printing compared to some other technologies, such as FDM (Fused Deposition Modeling).

For Formlabs resin printers, single-color printing is easily achieved with the Color Kit. Additionally, there are several other ways to add color to parts, such as:

Printing with colored resins
Dyeing post-printed SLA parts
Painting with acrylic paints
Filling hollow parts with color

Each method is suitable for different applications, considering surface quality, color durability, time, and production costs.

For more information, you can consult the guide that explains the appropriate use of each method, along with detailed step-by-step instructions, to effectively choose the coloring technique suitable for each type of part.

Fragrance

What started as an April Fools’ Day joke has now become a reality — this 3D printed strawberry smells just like a real one.

Creating scented 3D printed parts is possible by adding Fragrance Oil to the resin before printing begins. Once printed, the part will emit the scent of the added oil.

If you wish to try this yourself, you can follow a detailed guide explaining the formula, ingredients, and steps to create your own scented 3D printed parts.

Electroplating

The smooth and highly detailed surfaces of parts produced with SLA 3D Printing technology are ideally suited for electroplating.

Electroplating allows the integration of metallic properties such as:

Strength
Electrical conductivity
Wear resistance
Corrosion resistance
Aesthetic metallic finish

with other materials that have their own unique advantages, such as plastic parts produced with 3D printing.

Stereolithography (SLA) technology is particularly suitable for electroplating because it can produce parts with extremely smooth surfaces and high detail. This ensures a seamless and integrated bond between the plastic and the electroplated metal layer.

Additionally, SLA parts can be made waterproof, preventing damage when immersed in the chemical solutions used in the electroplating process.

To learn more about electroplating, you can read articles or download our White Paper to discover approaches to electroplating SLA parts, including examples of real-world applications across various industries.

Polishing

Achieve a smooth surface by polishing the part with progressively finer abrasive materials, moving from coarse to fine, to gradually reduce surface imperfections and enhance overall smoothness.

A pen sander is suitable for creating consistent surfaces on parts with flat or slightly curved profiles.

Meanwhile, a rotary tool fitted with grinding, sanding, or polishing attachments is ideal for achieving a glossy and smooth finish on parts produced with SLA technology.

For parts with flat or slightly curved surfaces, a pen sander can also be used to improve surface quality and ensure a consistent finish.

With the collaboration of experienced engineers and real users, we have curated a set of tools for finishing 3D printed parts. These tools are designed to improve surface quality, smooth surfaces, refine part edges, and enhance the overall appearance of the parts.

These tools also help reduce labor time and costs per part, making it easier and more efficient to create SLA parts with smooth and glossy finishes.

Priming, Spray Painting, and Coating

Protect surfaces and transform the appearance of 3D printed parts through Priming, Spray Painting, and Coating.

These processes enhance the aesthetic appeal of parts, increase surface durability, conceal manufacturing imperfections, and make parts more closely resemble final products. They also allow for customization of color, finish, and properties to suit specific applications or presentations.

Sanding parts to a smooth finish is the first step in painting 3D printed objects.

Once the surface is smooth, applying a primer prepares it for painting, ensuring better adhesion of the final color and a consistent, beautiful result.

After painting and finishing, a Clear Coat can be applied to protect the surface, enhance durability, and preserve the aesthetic appeal of the part over the long term.

For a complete list of required materials and equipment, as well as detailed step-by-step instructions, please refer to our guide.

Surface Texture

Create complex surface textures using Displacement Maps with the Formlabs Texture Engine, a free, lightweight web application designed to quickly add surface textures to 3D models, making them ready for 3D printing.

Many plastic parts feature added patterns or textures to improve both their appearance and tactile feel, or to enhance properties suitable for specific applications.

Traditionally, creating such textures often involves a post-production process. However, 3D printing allows textures and patterns to be directly integrated into the design file before printing. This results in parts with the desired surface details directly from the manufacturing stage, often eliminating the need for additional finishing processes.

Water Transfer Printing

Also known as Hydrographics, water transfer printing is a technique used to transfer complex graphic patterns onto 3D printed parts using a PVA (Polyvinyl Alcohol) hydrographic film.

Immersion printing is popular for decorating or customizing parts with desired graphic patterns. The part is submerged in a water tank where the patterned film floats on the surface. As the film partially dissolves, the pattern wraps around the part and transfers onto its surface.

This method offers significant advantages for parts with multi-directional curved surfaces or complex geometries, as these are difficult to decorate with graphic patterns using other methods.

In 3D model design, Texture Images are often used, which are surface images placed on the model via a UV Map—a plan defining the position of the image on the model's surface.

By printing the customized UV Map onto hydrographic film, these patterns or textures can be directly transferred to the 3D printed part.

Unlike general water transfer printing, which uses continuous repeating patterns, transferring patterns from UV textures requires precise alignment with the model's surface. Therefore, the behavior of the film as it wraps around the part must be simulated and predicted to ensure the pattern is transferred to the correct position as designed.

Read our guide to learn how to transfer full-color patterns onto parts using Computational Hydrographics, a water transfer printing technique that uses computational simulation to precisely position patterns on the part's surface.

This technique enables accurate transfer of complex images, graphics, and patterns onto three-dimensional parts, even those with curved surfaces or intricate geometries.

Elevating 3D Printing

Formlabs resin 3D printers can be applied across a wide range of industries, from engineering and manufacturing, dental and medical, to aerospace and entertainment.

The Form 4 series of 3D printers utilizes Masked Stereolithography (MSLA) technology, a new evolution of SLA 3D printing, delivering exceptionally high print speeds while maintaining excellent dimensional accuracy and surface quality.

With user-friendly workflows and high reliability, the Form 4 and Form 4L make 3D printing easier, allowing users to focus on developing new ideas and innovations rather than troubleshooting printing issues.

Explore Formlabs resin 3D printers or consult a 3D printing expert to discover how 3D printing technology can help you achieve your product development, manufacturing, and innovation goals.

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