Published on Sun Dec 24 2023 15:39:41 GMT+0000 (Coordinated Universal Time) by Alex

Formlabs Form 2: A Deep Dive into Resin Printing Excellence

The Formlabs Form 2 was a pivotal printer in democratizing resin 3D printing, bringing professional-grade quality to a wider audience. While it’s no longer the newest model on the market (Form 3 and beyond have followed), it remains a compelling machine, especially in the used market or for those looking for a proven and reliable system. Let’s break down what made the Form 2 a success.

Under the Hood: Detailed Specifications

Before we get into the experience, it’s important to know what the Form 2 is capable of:

• Print Technology: Stereolithography (SLA)
• Build Volume: 145 x 145 x 175 mm (5.7 x 5.7 x 6.9 inches)
• Layer Resolution: 25 - 100 microns (0.001 - 0.004 inches)
• Laser Spot Size: 140 microns (0.0055 inches)
• Laser Power: 250mW
• Materials: Formlabs proprietary resins (various types: standard, engineering, dental, castable, etc.)
• Connectivity: Wi-Fi, Ethernet, USB
• Software: Formlabs PreForm
• Physical Dimensions: 35 x 33 x 52 cm (13.8 x 13 x 20.5 inches)
• Weight: 13.5 kg (29.8 lbs)

These specifications tell a story. The laser-based SLA process, combined with fine layer resolution, promises highly detailed prints. The build volume is decent for desktop SLA, allowing for larger single prints or multiple smaller components in a single job. The reliance on proprietary resins is both a blessing and a curse (more on that later).

Getting Started: Usage Tips and Best Practices

The Form 2 is generally straightforward to use, but here are some tips to optimize your printing experience:

1. Mastering PreForm: Formlabs’ PreForm software is your best friend. It automatically orients parts, generates supports, and slices your models. Take the time to learn its advanced features, such as manual support editing and hollowing techniques, to minimize resin usage and print time.

2. Orientation is Key: The orientation of your model significantly impacts print success. Avoid printing large flat surfaces parallel to the build platform, as they can lead to warping or detachment. Angle your parts strategically to minimize support structures and ensure proper drainage.

3. Support Placement: Supports are crucial in SLA printing, but they also leave marks on the final print. Experiment with support density, touchpoint size, and placement to find the optimal balance between support and surface finish. Try to place supports on less visible areas of the model.

4. Resin Handling: Resin is photosensitive and can be messy. Always wear gloves and eye protection when handling it. Store unused resin in its original container in a dark, cool place. Avoid prolonged exposure to sunlight.

5. Tank Management: Regularly inspect and clean the resin tank. Remove any debris or cured resin particles. Consider replacing the tank periodically, especially if you notice a decrease in print quality.

6. Post-Processing is Essential: SLA prints require post-processing, including washing in isopropyl alcohol (IPA) to remove uncured resin, followed by UV curing to fully harden the material. Invest in a proper washing station and UV curing chamber for consistent and high-quality results. Formlabs Wash and Cure units are ideal but other options exist.

7. Resin Selection: Choosing the right resin is critical for your application. Consider factors like mechanical properties, temperature resistance, chemical compatibility, and aesthetic requirements. Consult Formlabs’ material data sheets for detailed specifications.

8. Leveling: The Form 2 relies on a precise and well-calibrated leveling. If you start seeing adhesion issues or misshapen parts, double-check that the build platform is secure and the machine is level.

9. Monitor Prints: Pay close attention to the first few layers of each print. If you notice any issues with adhesion or support formation, stop the print immediately to avoid wasting resin and time.

10. Maintenance: Clean the optical window regularly. Dust and fingerprints can distort the laser and affect print quality. If you encounter persistent printing problems, consult Formlabs’ support documentation or contact their customer support team.

Strengths of the Form 2

• High Print Quality: SLA technology allows for exceptional detail, smooth surfaces, and tight tolerances.
• Wide Range of Materials: Formlabs offers a diverse portfolio of resins for various applications, including engineering, dental, and jewelry.
• Reliability: The Form 2 is a relatively mature and reliable platform, with a large user base and plenty of community support.
• User-Friendly Software: PreForm is intuitive and easy to use, even for beginners.

Potential Drawbacks

• Proprietary Materials: The Form 2 primarily works with Formlabs resins, which can be more expensive than third-party options.
• Post-Processing Requirements: SLA printing requires significant post-processing, including washing and curing, which can be time-consuming and messy.
• Build Volume: Compared to some FDM printers, the Form 2’s build volume is relatively small.
• Price (New): When initially released, the Form 2 was positioned at a higher price point than many entry-level FDM printers. Prices may vary drastically if the machine is used.

Form 2 Evaluation: Points out of 10

Here’s a breakdown of the Form 2’s performance in various categories, rated out of 10:

• Print Quality: 9.5 - Excellent detail and smooth surfaces. Near perfect.
• Build Volume: 7 - Decent for desktop SLA, but limited compared to some FDM alternatives.
• Printing Speed: 6 - SLA printing is generally slower than FDM.
• Material Compatibility: 7 - Primarily limited to Formlabs resins, but a wide range within that ecosystem.
• Bed Adhesion & Leveling: 8 - Reliable adhesion with proper setup and maintenance.
• Reliability: 8.5 - Proven track record and a large user base.
• Ease of Use: 8 - PreForm software is user-friendly, but post-processing can be challenging.
• Firmware and Software: 8 - PreForm is well-designed and regularly updated.
• Connectivity Options: 7 - Wi-Fi, Ethernet, and USB provide flexible connectivity.
• Build Quality & Durability: 8 - Sturdy construction and durable components.
• Noise Level: 7 - Relatively quiet compared to some other 3D printers.
• Maintenance Requirements: 6 - Regular tank cleaning and optical window maintenance are necessary.
• Customer Support: 7 - Formlabs provides decent customer support, but response times can vary.
• Upgradeability: 4 - Limited upgrade options.
• Price to Performance Ratio: 7 - When purchased new, the price was high but now that the machines are only available used it provides a very good price to performance ratio.

Average Score: 7.43/10

The Verdict

The Formlabs Form 2 was a groundbreaking 3D printer that brought high-resolution resin printing to a wider audience. While it has been superseded by newer models, its reliability, print quality, and ease of use make it a solid choice, especially if you can find one on the used market. If you’re looking for a printer that can produce highly detailed and accurate parts, and you’re willing to invest in the required post-processing equipment, the Form 2 is definitely worth considering. Just remember to factor in the cost of proprietary resins when making your decision.

Written by Alex