Over the past decade, advancements in technology have made resin 3D printing, also known as vat photopolymerization, one of the primary methods for producing high-detail 3D prints for rapid prototyping, rapid tooling, manufacturing aids, and even end-use parts, due to its high precision, fast print speeds, wide range of materials, and isotropic mechanical properties.
As manufacturers of resin 3D printers have introduced innovations in hardware, software, and materials science, different types of resin 3D printing processes have become more prevalent.
For many years, the two primary types of resin 3D printers were broadly defined as stereolithography (SLA) and digital light processing (DLP). More recently, sub-categories of those technologies have been introduced and more clearly delineated, including liquid crystal display (LCD) and masked stereolithography (MSLA) 3D printing.
While all these resin 3D printing technologies were once prohibitively complex and expensive, today, compact desktop and benchtop resin 3D printers can produce industrial-quality parts at an accessible price point, and with excellent mechanical and aesthetic properties.
This guide will cover the specifics and advantages of each type of resin 3D printing process, including a discussion of cost and the applications each printer type might work best for.
What is SLA 3D printing?
Traditional SLA printers were built around large resin tanks filled with liquid resin, the top layer of which was selectively cured by a laser positioned above the tank. These systems were large, prohibitively expensive, and required complex infrastructure, limiting their adoption primarily to Fortune 500 companies.
Formlabs introduced inverted stereolithography 3D printing in 2011 with the Form 1. With inverted SLA, the light source, a laser in the Form 1, cures a cross-section of the part through the transparent bottom of the resin tank. This means that only a thin layer of resin needs to be dispensed, and only that amount of resin is available to be cured at any given time. This technology made it possible to produce resin parts using much smaller printers that can sit on a workbench.
A graphic illustrating Formlabs’ Low Force Stereolithography™ (LFS) Print Engine, an advanced form of SLA 3D printing.
With the release of the Form 2 in 2015 and the subsequent release of more varied materials, SLA 3D printing became dramatically more reliable and useful for professionals in a wide variety of different environments.
In 2019, Formlabs introduced Low Force Stereolithography (LFS) with the Form 3 and Form 3L SLA 3D printers, which use a flexible-bottom resin tank to peel the cured part away from the bottom of the tank, dramatically reducing the forces exerted on the part during the print process.
This advanced form of stereolithography delivered vastly improved surface quality and print accuracy. The lower print forces also enable light-touch support structures that tear away easily, larger build volumes, and open up advanced materials ready for production.
What is DLP 3D printing?
Digital light processing (DLP) 3D printing is a resin 3D printing process that uses a projector rather than a laser to cure liquid resin layer by layer.
The light source for DLP printers is projected using an array of micromirrors arranged in a matrix on a semiconductor chip. Each of these micromirrors represents a single voxel, or a single 3D pixel, of the part. The number of micromirrors and the size of the build area dictates the part’s resolution.
A graphic illustrating digital light processing (DLP) 3D printing.
Because light is simultaneously projected across the entire cross-section of the part, each layer is cured very quickly. For this reason, DLP 3D printers generally offer faster print speeds.
In the same way that inverted SLA 3D printing gave rise to desktop machines, rather than the large, top-down traditional printers, inverted DLP printers also became more accessible and affordable with more compact, desktop machines.
What is MSLA or LCD 3D printing?
Masked stereolithography (MSLA) 3D printing refers to any photopolymerization process where the light source is masked, or selectively masked. It is often used interchangeably with LCD 3D printing because MSLA printers typically use an LCD screen to mask light and selectively cure the desired cross-section of the part. However, MSLA can also refer to other technologies as well, as it refers to masked resin 3D printing, regardless of the light source type or masking technique.
A graphic illustrating Formlabs’ Low Force Display™ (LFD) Print Engine, an advanced form of MSLA 3D printing.
The use of LCD screens in resin 3D printing came after the development of laser-based SLA 3D printing and DLP 3D printing, enabled by the rapid development of display technology. Because these technologies were becoming so ubiquitous in other types of electronics, it became possible to design LCDs that had small pixel sizes and high light transmittance at the 405 nanometer wavelength typically used to cure liquid resin.
Because the LED array projects light simultaneously, MSLA 3D printers cure each layer of resin almost instantaneously and deliver fast print speeds comparable to DLP 3D printers.
The denser the LCD screen, the smaller the pixels, and the higher the possible resolution of the part. However, there is a trade-off with smaller pixels. Higher pixel density, or smaller pixels, leads to lower light transmittance, resulting in lower light power delivered to the liquid resin, and thus slower print speeds.
Formlabs’ Low Force Display™ (LFD) Print Engine is an advanced form of MSLA 3D printing, developed for the Form 4 and Form 4L. LFD introduces an entirely new suite of technologies, including a backlight unit, light processing unit, release texture, and integrated cameras, as well as significant improvements to the flexible film tank, resin cartridge, automated resin handling, and intelligent control system, to deliver the speed, reliability, and part quality professionals demand, all in one printer.
SLA, DLP, MSLA/LCD 3D Printing Processes Compared
Laser-based SLA, DLP, and MSLA/LCD 3D printers are all stereolithography processes because they all use a light source to cure liquid resin. Some of the differences between these resin 3D printing technologies stem from the precision, resolution, quality, and durability of that light source, the light processing solution, and other technologies built around them. Other differences, such as workflow or applications, will vary more from manufacturer to manufacturer, depending on the software, accessories, and materials available for each system.
Resolution
Resolution in 3D printing can be difficult to characterize and standardize across machines and manufacturers. Ultimately, print quality and accuracy depend on many factors: the size, shape, and power distribution of the light that cures the resin, as well as the scattering, bleed, and polymerization characteristics of the resin. For example, some resins scatter light more than others, which can cause excess resin to cure and create less detailed features in the print.
Resolution, once called ‘dots per inch’ or DPI in paper and ink printers, could easily be understood as the ink covering the X and Y axes. As 3D printing became more prevalent, the addition of the Z-axis further complicated the definitions and measurement standards for 3D print resolution.
To determine which 3D printing technology and manufacturer is truly the highest resolution, one should consider both the ability to specifically trace features in the XY plane and the minimum Z-axis layer height. However, the ability to trace features to their intended pattern relies on many factors.
Resin 3D printers offer excellent resolution, significantly higher than other 3D printing processes such as fused deposition modeling (FDM) 3D printers. For applications such as rapid prototyping or molding, resolution can mean the difference between a successful final product or design review.
Resolution for laser-based SLA 3D printers is determined by four factors: the laser spot size, the power distribution of the laser spot, the precision with which the galvanometers can position the light in the XY plane, and the minimum Z-axis layer height.
At first glance, the laser spot size would appear to indicate the minimum feature size possible, but this isn't true. While it is true that if an entire part consists of only a single circular dot or sphere, the minimum feature size would be dictated by the laser spot size because it cannot cure something smaller than itself. However, a single, very small dot or spherical part is not realistic. For a realistic part, the laser can trace shapes and features smaller than its spot size because it can move in the XY plane in increments smaller than its own spot size, tracing along the “outside” of a very small feature.
For example, the Form 3+ has an 85 micron laser spot size, but a 25 micron XY resolution. Here, XY resolution refers to the precision with which the printer can draw in the XY, or horizontal, plane.
The resolution of DLP 3D printers is determined by the pixel size, both X and Y measurements, the power and uniformity of the light, the use of anti-aliasing, and the minimum Z-axis layer height, similar to laser-based SLA printers.
The smaller the pixel size, the higher the resolution, similar to familiar technologies such as televisions or portable electronic devices. In DLP 3D printing, the XY resolution is dictated by the pixel size, which is the smallest feature the projector can reproduce within a single layer. This depends on the resolution of the projector, most commonly full HD (1080p), and the projector's throw distance from the optical window. For this reason, most desktop DLP 3D printers have a fixed XY resolution, typically between 35 and 100 microns.
The resolution of DLP 3D printers decreases as the build volume increases, as there are no significantly higher pixel count projectors available. Thus, manufacturers must increase the throw distance from the light source with the same number of pixels, which leads to reduced resolution and print quality.
The resolution of MSLA 3D printers is determined by the pixel size of the LCD, the collimation and uniformity of the light source, the use of anti-aliasing, and the minimum Z-axis layer height.
Similar to DLP 3D printers, the smaller the pixels, the higher the resolution, but smaller pixels are only one factor. MSLA printers need highly collimated light, meaning the light rays are parallel and do not diverge as they pass through the pixels in the LCD screen. The light also needs to be incredibly uniform, so that resin is cured with equal light power through every pixel in the LCD screen.
Fortunately, the minimum Z-axis layer height is less complex. Most resin 3D printers have a standard layer height between 25 and 200 microns. For inverted resin 3D printers, layer height is determined by the vertical depth of resin squeezed between the build platform and the bottom of the resin tank, which is effectively the height of the resin cured in each layer.
In short, does resolution really matter in resin 3D printing? The answer is yes, but resolution itself is often only a vanity metric. It offers some indication, but doesn't necessarily correlate directly to accuracy, precision, and print quality. Higher resolution, which means smaller pixels or laser spot sizes in the XY dimension and smaller layers in the Z dimension, also typically comes with significant tradeoffs in speed, or even reliability, as a greater number of layers can introduce more possibilities for errors.
For a real-world example, read our study assessing how SLA and MSLA 3D printers with different resolutions perform in terms of surface finish, dimensional accuracy, and minimum feature size.
Dimensional Accuracy & Precision
Because 3D printing is an additive process, each layer introduces an opportunity for dimensional inaccuracy. As each layer builds, very small deviations from the intended cross-sectional shape can accumulate, affecting the overall accuracy. Accuracy depends on several different factors: the type of 3D printing process, the hardware design, the resin properties, print settings, and post-processing workflow. Generally, resin 3D printers are the most accurate and precise 3D printing process. The differences in accuracy and precision will vary more by model and manufacturer than by technology.
In resin 3D printing, the first major factor affecting accuracy is the optical performance of the printer, specifically the size, shape, and uniformity of the light that cures the resin. Professional laser-based 3D printers such as the Form 3+ and Form 3B+ use high-quality galvanometers and extensive calibration to ensure that the laser’s light lands exactly where it is intended on the resin, and follows the laser path without deviation.
The accuracy of DLP 3D printers is affected by the resolution and power of the light projector, as well as the quality and calibration of the micromirror array. DLP printers are often limited in accuracy by pixel distortion at the edges of the build area, where the micromirror array has to project light farther away from the light source.
Dimensional accuracy and precision are important for 3D printed parts that will be part of an assembly, or need features for inserted components, such as these pinholes for an electronic circuit board assembly.
The accuracy of LCD and MSLA 3D printers is affected by the uniformity and collimation of the light source, as well as the pixel size and quality of the LCD screen. Most LCD printers have a lens over the light source, but most are very basic lenses and can lead to non-uniform light, dark spots, or distortion, which creates inaccurate parts. The quality of the LCD screen is also critically important. Higher quality means that the LCD screen will respond to the software programming that tells the screen where to mask light, and where to let light pass.
The Formlabs Light Processing Unit 4 (LPU 4) features a custom 50 μm pixel LCD screen and pre-tuned anti-aliasing for excellent dimensional accuracy. The Form 4’s Backlight Unit creates a uniform area projection of ultra-high power light, using 60 LEDs and an array of plano-convex lenses, as well as an optical baffle, which creates highly collimated and uniform light, even at high power.
The second major factor affecting accuracy is the forces exerted on the part during printing. All inverted resin printers experience two types of print forces. Peel forces occur during the peel process of each layer, as the build platform lifts up and the cured layer separates from the resin tank before beginning a new layer. Squish forces occur on each layer as the build platform moves down and squishes the print into the pool of liquid resin. These forces can cause layers to shift and warp, ultimately leading to lower dimensional accuracy.
Some printers use basic flexible film resin tanks that gently separate from the cured layer and minimize peel forces. While these tanks reduce peel forces, they have two main issues: they use non-durable film that damages easily and needs to be replaced frequently, and they are prone to suction forces, which is when the flexible film adheres to the LCD screen and dramatically increases peel forces.
The Form 4 and Form 4L, professional MSLA printers, use a durable, dual-layer flexible film tank that minimizes peel forces and is highly resistant to damage. The Form 4 and Form 4L also feature a proprietary microtextured optical film called Release Texture, which allows air to flow between the resin tank and LCD screen, preventing suction forces and improving accuracy.
The Release Texture of the Form 4 MSLA 3D printer allows air to flow between the resin tank and LCD screen, preventing suction forces and improving accuracy.
The last major factor impacting accuracy is the properties of the liquid resin inside the printer. The process of curing liquid resin depends on numerous variables, including the resin’s temperature, homogeneity, scatter, viscosity, and more. Small changes to any of these variables can cause the resin to cure more or less, which can lead to hundreds of micrometers of deviation in the size or shape of the cured layer. Most resin 3D printers do not control these variables, resulting in frequent and unpredictable changes in dimensional accuracy.
The Form 4 and Form 4L address this issue in several ways. First, they precisely control the temperature and homogeneity of the liquid resin, utilizing a high-precision heater, infrared temperature sensing, and a high-speed resin mixer. Formlabs also develops and manufactures its own materials, and tightly controls the reactivity, viscosity, and scatter properties of every material. Additionally, the Form 4 and Form 4L utilize advanced slicing software, printer hardware calibration, and validated print settings to automatically compensate for the properties of each individual material.
Once again, the accuracy and precision of a 3D printer depend not only on the technology but on specific hardware design, the properties of the liquid resin, print settings and calibrations, and post-print workflow.
Build Volume
Before the introduction of inverted SLA 3D printing, resin 3D printers had large build volumes and were extremely expensive. Inverted resin 3D printing then made the technology more accessible, but these machines were often much smaller, as larger builds were extremely difficult to print successfully due to high peel forces.
Today, a combination of inverted SLA, which only requires as much resin as is needed rather than an entire large resin tank, and new peel technologies, allows for printing with much larger build volumes without having to pay more than $100,000 USD for traditional large format resin 3D printing systems. For industries like consumer goods, product design, and healthcare, large format resin printers are an ideal solution and enable applications like human-sized parts.
Those looking to evaluate which size resin printer is best for them should consider the application first. There are three main product categories for laser-based resin printers: desktop, benchtop, and industrial-sized systems.
Benchtop resin 3D printers, like the Form 4L, offer a combination of human-sized parts with the dimensional accuracy, material property range, and surface finish of resin 3D printing.
Industrial-sized systems were more common in earlier decades for large companies that could bear both the high purchase and maintenance costs, as well as the greater space and infrastructure requirements of top-down stereolithography.
Desktop resin 3D printers were made possible by the invention of inverted SLA 3D printing, and as this technology was adopted by more manufacturers, smaller machines with build areas of roughly 10-20 cm cubed in each direction became standard. For example, Formlabs’ Form 3+ has a build volume of 14.5 × 14.5 × 19.3 cm, while the Form 4 offers a 30% larger build volume at 20.0 × 12.5 × 21.0 cm.
Benchtop resin 3D printing similarly arose from a combination of inverted SLA technology and improved peel techniques. Benchtop 3D printers like the Form 4L, which has a build volume of 35.3 × 19.6 × 35.0 cm, are capable of human-sized rapid prototyping for consumer goods, as well as creating products for direct-use applications or through 3D printed rapid tooling.
For DLP 3D printers, there is a direct trade-off between resolution and build volume. Resolution is dependent on the projector, which determines the number of available pixels/voxels. If the projector is moved closer to the optical window, pixels become smaller, which increases the resolution, but limits the available build area. Some manufacturers use higher resolution 4K or 8K projectors, but these are extremely expensive, driving up the cost of the final product.
Most large format DLP printers still use top-down rather than inverted technology, which requires large quantities of resin to be available at once. As such, desktop and smaller format DLP 3D printers are typically optimized for niche use cases. They have smaller build volumes and offer high resolution to produce small, detailed parts, such as jewelry, while others can produce larger parts, but at a lower resolution.
Since LCD 3D printers rely on a similar sized LED array and LCD mask screen, the accuracy and precision benefits remain the same as the build volume gets larger. Large format LCD or MSLA resin 3D printers will be just as accurate as smaller versions, provided they use LCD screens with the same pixel size, and LED light sources with the same level of uniformity and beam collimation.
However, unlike laser-based SLA 3D printers, this does incrementally add cost for every additional LED and every additional square centimeter of LCD screen. Laser-based resin printers can use the same laser for any build volume size, as its galvanometers can easily route it to farther reaches of the build platform for larger dimensions. However, for print speed benefits, many large format benchtop laser-based resin printers, such as the Form 3L, add a second laser unit, which adds cost in a similar manner to adding additional LED arrays and larger LCD screens.
Surface Finish
Resin 3D printers are known for producing smooth surface finishes that require little post-processing to achieve an injection molded plastic-like appearance. Resin 3D printing, whether it uses a projector, LED array, or laser, can cure liquid resin with a significantly better surface finish than filament-extruding FDM printers. Depending on the design, all resin and FDM printers may need to print parts with supports, which can leave touch points or blemishes on the surface that might need light sanding or snipping off.
The possible surface finish on the Form 4L allows for more realistic human-sized prototypes — this steering wheel prototype features the tactile surface of what would eventually be the upholstery for a real-life application, built into its 3D model.
The layers of resin 3D printers are bonded together both chemically and physically in the Z-axis, so the vertical differentiation between layers is very hard to detect, resulting in a smoother appearance.
For clear materials, like Clear Resin, this smooth surface translates to a better transparency of the part itself, making it an ideal technology for parts that require optical translucency, or the display of internal features.
The smooth surface allows for nearly completely optical transparency. For two-part molds, this transparency makes it easier to observe and correct molding process issues as they happen within the part.
Laser-based 3D printers, like the Form 3+ and Form 3L, are prized for their nearly flawless surface finish. Since the laser has a circular spot size, curved edges are truly rounded, and the overall appearance of the part is very smooth.
DLP and LCD 3D printers also typically have very smooth surface finishes and require very little sanding or polishing to appear like injection molded plastic. However, both DLP and LCD printers project light through rectangular voxels or pixels. Historically, these voxels would result in visible “stair-stepping” or “aliasing” artifacts in the X and Y axes, commonly referred to as voxel lines or pixel lines.
More recently, DLP and LCD 3D printers have begun to utilize higher resolution projectors or LCD screens with very small pixels, in combination with anti-aliasing techniques, where some pixels are only partially activated. As a result, newer DLP and LCD 3D printers offer a surface finish that is largely indistinguishable from laser-based SLA printers.
Speed and Throughput
As more businesses turn to 3D printing for production, as well as rapid iteration and improvement, 3D print speed becomes a greater consideration when selecting a technology. The right 3D printer is one that produces high-quality parts quickly, without compromising accuracy, reliability, or material performance. FDM and SLS processes have significantly improved print speeds, but resin 3D printers have gotten even faster, making them the fastest additive manufacturing processes. New Print Engines like LFD take that even further, and can produce most parts in just a few hours, or small parts in a matter of minutes.
For small parts, laser-based resin printers are comparable in speed to DLP and LCD 3D printers — when the laser does not need to cover a large area to cure the resin, it can complete each layer very quickly. However, for medium to large parts, or batch production, laser-based 3D printers can be significantly slower than their DLP or MSLA counterparts.
DLP printers have gained popularity in industries where rapid printing impacts the bottom line, such as dental labs. However, they are more prone to optical distortion across the build area and require advanced calibration to achieve high accuracy. They are also generally more expensive than LCD 3D printers for comparable performance.
Advanced MSLA technologies, like the Form 4 and Form 4L, offer the fastest and most reliable 3D printing solution overall. Curing entire layers at once is the biggest factor driving that speed, but other factors, like the Form 4’s dual-layer flexible resin tank, Release Texture, high-speed automated resin filling, and rapid resin heating also contribute to reducing overall print time.
The Form 4 can complete a full build area print in 2-5 hours, depending on material. The throughput possible with an affordable, fast, and easy-to-use 3D printer fleet, such as the Form 4, can rival the output of traditional processes like injection molding.
When considering MSLA printers for production, component quality and reliability are critical considerations. Most LCD printers have a reputation for short lifespans, as commodity LCD screens are not produced for the types of conditions found in 3D printers. An LPU is a long-lasting component, and should last at least a year under average use. That lifespan may be closer to three months in high-volume production environments.
Scaling throughput is easy with desktop resin 3D printers. The accessible size of these machines makes it simple to add more machines and scale to produce more parts. Additionally, there are options to add automation for some machines. Formlabs’ resin printers feature advanced workflow tools like the Form Auto for the Form 3/B/+ that automates part removal, allowing for 24/7 printing. Automated tools like the Formlabs Automation Ecosystem reduce the number of touchpoints needed in the print process, making workflows that require printing many small, largely similar parts, such as dental or orthodontic models, nearly continuous.
Print Speed Comparison: Game Controller
| Item | FDM 3D Printing | SLA 3D Printing | SLS 3D Printing |
|---|---|---|---|
| 1 Assembly (3 parts) | 10 h 32 min | 2 h 36 min | 3 h 52 min print (6 h 52 min cool-down) |
| 5 Assemblies (15 parts) | 52 h 40 min | 13 h | 9 h 38 min print (13 h 47 min cool-down) |
Printers and print parameters compared:
FDM 3D Printer: Bambu Lab X1, PLA Basic, 120 micron layer height, 15% infill density
SLA 3D Printer: Form 4, Grey Resin, 100 micron layer height
SLS 3D Printer: Fuse 1+ 30W, Nylon 12 Powder, 110 micron layer height
Print Speed Comparison: Electrical Connector
| Item | FDM 3D Printing | SLA 3D Printing | SLS 3D Printing |
|---|---|---|---|
| 1 Assembly (2 parts) | 2 h 38 min | 1 h 3 min | 3 h 30 min print (6 h 27 min cool-down) |
| 50 Assemblies (100 parts) | 84 h | 13 h 2 min | 12 h 59 min print (13 h 49 min cool-down) |
Printers and print parameters compared:
FDM 3D Printer: Bambu Lab X1, PLA Basic, 120 micron layer height, 15% infill density
SLA 3D Printer: Form 4, Grey Resin, 100 micron layer height
SLS 3D Printer: Fuse 1+ 30W, Nylon 12 Powder, 110 micron layer height
Print Speed Comparison: Radio Flyer Seat Prototype
| Item | FDM 3D Printing | SLA 3D Printing |
|---|---|---|
| 1 Prototype | 42 h 3 min | 2 h 37 min |
Printers and print parameters compared:
FDM 3D Printer: Ultimaker S7, PLA, 100 micron layer height, 20% infill density
SLA 3D Printer: Form 4, Fast Model Resin, 200 micron layer height
Interested in checking print speeds for your own parts? Download PreForm, Formlabs’ free print preparation software, to calculate print times when printing on Formlabs’ SLA and SLS 3D printers.
Workflow and Ease of Use
Each manufacturer will offer a range of workflow solutions to make resin 3D printing easier.
Some printers come with manufacturer-specific software for preparing 3D models for printing, such as PreForm for Formlabs’ SLA 3D printers, while other manufacturers may require users to purchase slicing software to orient parts, generate support structures, slice models into layers, and manually upload files. Features will vary across software tools. For example, PreForm offers one-click print settings, powerful manual controls to optimize support density and size, adaptive layer thicknesses, or material and time-saving functions. Luckily, software is easily downloadable and available to try before purchasing a 3D printer.
Getting started with resin 3D printing can be fairly straightforward. Many resin 3D printers, especially desktop machines, are designed to be unboxed in a matter of minutes and to start printing almost immediately. Parts of the process, such as user interfaces and in-printer sensors, not only simplify a first print, but also ongoing maintenance.
Some low-cost resin 3D printers require additional calibration steps to ensure material will successfully print at a given layer height. These steps can include manually pouring resin, selecting print settings, without the benefit of a validated and repeatable workflow, and fine tuning print settings to ensure parts will succeed.
The improved user experience on the Form 4 includes a touchscreen that is both easier to read and easier to interact with.
The Form 4 and Form 4L's improved touchscreen, smart controls, and fast, automated resin dispensing create a seamless workflow that allows users to "set it and forget it," enabling them to focus on their designs and tests while the Form 4/L delivers the part. An advanced cartridge system automatically fills the tank with liquid resin, requiring less attention and enabling overnight printing. Validated material settings for multiple layer heights provide peace of mind for users, who can select a material and layer height knowing they have undergone rigorous testing and that the printer will successfully complete the part.
Another important factor to consider when choosing a 3D printing system is the post-printing workflow. Once printing is complete, parts must be washed, possibly post-cured, and then undergo post-processing, whether it's simple support removal or more advanced post-processing methods. The lower peel forces of the Form 4 allow for supports with very small contact points that are easy to remove. These light-touch supports lead to faster post-processing times and a simplified workflow.
Each manufacturer offers a variety of solutions, such as Formlabs' integrated workflow that utilizes automatic IPA agitation in the Form Wash, pre-programmed post-curing settings for over 40 materials in the Form Cure, and an advanced Finishing Tools kit for sanding, polishing, and preparing parts for use.
Materials and Applications
Regarding easy switching between materials, most resin printers are "plug and play" with easily interchangeable build platforms and resin tanks. As with accuracy and precision, the available materials vary more between individual machines than between technologies. Many manufacturers produce their own resins, but many do not, choosing to rebrand materials from other companies or simply offering an open system that can accommodate multiple types of resins.
|
 |
| Formlabs' Flame Retardant Resin is a specialized material with UL 94 Blue Card certification for creating self-extinguishing and halogen-free parts. |
Silicone 40A Resin is a true silicone, offering mechanical properties familiar to engineers and product designers. |
The advantage of an open system is easily identifiable: it gives users more control over selecting any material they desire. However, the trade-off is that these open systems do not specifically calibrate material settings for their own printers. Consequently, the accuracy, reliability, and material properties are often affected. Formlabs offers both a unique library of over 40 proprietary resin formulations and the ability to use third-party certified materials through its Open Platform. Some of these specific materials are designed for niche and extreme applications, such as open flame environments, waterproof enclosures, or injection molding.
Materials are often the deciding factor in unlocking different applications. Some applications, such as electronics manufacturing, require specific formulations and third-party certifications, such as electrostatic dissipative resins. Other applications, like manufacturing aids, require strong and durable resins. Many manufacturers offer resins that can meet these properties, although strength and durability vary between manufacturers. When choosing a resin 3D printer, consult the material's technical data sheet to determine if the specific resin formulation can withstand your intended application, and the safety data sheet to ensure the resin is safe to use.
|
 |
| Rigid 10K Resin is a highly glass-filled, exceptionally stiff material, similar to glass and fiber-filled thermoplastics. This material is ideal for rapid tooling applications such as injection molding, blow molding, or thermoforming. |
BioMed Elastic 50A Resin allows healthcare providers to 3D print soft, flexible, and biocompatible parts with complex geometries, such as patient-specific medical devices or soft tissue medical models. |
Cost
Traditionally, resin 3D printers have been more expensive than FDM 3D printers but less expensive than SLS printers, though there are exceptions. In recent years, however, prices have come down, and resin printers now offer the best value for an increasing range of applications.
At the lower end of the price spectrum, low-cost LCD 3D printers are available for $200 to $1000 USD. These machines may be suitable for hobbyists or beginners but require calibration and fine-tuning for each resin type and are generally less reliable or durable, often leading to higher costs in terms of maintenance, downtime, failed prints, and wasted material.
Professional resin 3D printers, encompassing SLA technologies including laser-based SLA, DLP, or LCD/MSLA, generally range from $2,500 to $10,000 USD, while large-format resin 3D printers typically fall between $5,000 and $25,000 USD. Numerous factors influence prices within this range, from more reliable and powerful light sources, whether LED, laser, or projector, to light processing solutions, overall build quality, software, accessories, and service plans.
Similarly, material costs vary by manufacturer. As mentioned above, many manufacturers outsource or simply rebrand materials from other suppliers, which can add additional cost overhead to materials. Low-cost materials, like low-cost resin printers themselves, can negatively impact your print quality and create hidden costs, as can using materials that have not been validated and calibrated for a specific machine. Some low-cost materials also produce strong odors or contain ingredients that allow them to be produced at a lower cost but are not certified for safe handling and use.
Formlabs materials are validated for specific use cases and engineered precisely to perform optimally across a range of environments and applications. By investing both time and labor into print settings for each layer height and each material, Formlabs ensures that each of its 40+ resins is safe and easy to use.
Getting Started with Resin 3D Printing
When deciding between laser-based SLA, DLP, LCD, and MSLA technologies, consider your intended applications and, consequently, the most suitable materials, as well as other factors such as speed, accuracy, and resolution.
While these resin 3D printing processes have some differences, major differences in machine performance often stem from variations in manufacturer choices rather than the inherent strengths and weaknesses of the process itself.
Resin 3D printing as a broad category can produce parts with very high precision and accuracy, smooth surface finishes, and faster than any other technology. These parts can cover a wide range of applications due to their specific resin formulations. Professional resin 3D printers, such as Formlabs' Form 4, combine the high speed of resin 3D printing with the surface resolution and accuracy of high-end industrial 3D printers and offer a wide variety of advanced materials, showcasing the best features this technology can offer.
Learn more about the Form 4 and Form 4L, or delve into our material catalog to explore Formlabs' 40+ resins.
 |
Formlab Form 4 SLA machine details Click Check price Click |
 |
Formlab Fuse 1+ 30W SLS machine details Click Check price Click |
References
https://formlabs.com/global/blog/sla-dlp-msla-lcd-resin-3d-printer-comparison/
