Design Guide: How to Design for 3D Printed Parts on Form 4

A successful 3D print starts with a well-designed model. Like other manufacturing processes, there are limits to what 3D printing — and different types of 3D printing — can produce. 

Form 4 Series 3D printers — including Form 4, Form 4B, Form 4L, and Form 4BL — are built on groundbreaking Low Force Display™ (LFD) technology. Form 4 Series printers  redefine the industry performance standard and deliver unmatched reliability, fine details and surface finishes, and high-accuracy all at blazing fast speeds, expanding just what it’s possible to print with resin 3D printing. 

In the past, peel forces have been a major hurdle for resin 3D printing, forcing users to sacrifice either part quality, reliability, or printing speed when selecting a printer. With Form 4 Series printers, peel forces are minimized using a new Release Texture and redesigned Flexible Film Resin Tank, which introduces airflow to prevent the resin tank from suctioning to the Light Processing Unit. As a result, Form 4 Series printers can rapidly and reliably produce smooth, detailed parts with light touch supports that rival injection molding, with extreme print speed and reliability.

The Form 4 Design Guide is a handy reference developed by our engineers to help users create successful parts. It was developed using Grey Resin V5 printing at 50 μm on Form 4. Slight variations may occur if printing with other Formlabs resins, different Formlabs printers, and various layer thicknesses. The guide covers: 

• Minimum supported wall thickness and minimum unsupported wall thickness

• Maximum unsupported overhang length, unsupported overhang angle, and horizontal support bridges

• Vertical-wire diameter, embossed detail, engraved detail, clearance, hole diameter, and drain hole diameter

• Form 4 vs. Form 3 comparison

Learn more about some of the features the guide can help you print. Additionally, design guidelines can be applied to these advanced 3D printing techniques for users looking to level up their 3D printing.

Unsupported walls are connected to other walls on fewer than two sides. If a wall is less than 0.2 mm or 200 μm in width, it may be prone to wrapping or detaching during printing.

Overhangs are surfaces of a 3D print that stick out horizontally or parallel to the build platform. We recommend that unsupported overhangs not exceed 5.0 mm or 5,000 μm. If internal supports won’t affect the final part, they can be added in PreForm in order to reduce the likelihood of failure. Additionally, changing the orientation of the model can minimize the number of overhangs in the model.

Embossed details are shallow raised features, often text, while engraved details are imprinted or recessed. Embossing and engraving are often used for part names or identification codes, but can also be used for fine details.

Embossed and engraved labels can be added directly to models in PreForm, with options for font, size, and depth. We recommend that embossed details be no smaller than 0.1 mm or 100 μm, and engraved details be recessed no less than 0.15 mm deep or 0.15 mm wide.

Holes can be used in 3D printed parts including millifluidic devices, or as drain holes, which are used to drain resin from cups formed by part orientation and geometry when printing. It’s recommended that holes have a diameter of at least 0.5 mm or 500 μm when printing.

It is recommended that drain holes be a minimum of 0.75 mm or 750 μm. Without drain holes, parts with cups may trap resin or air, leading to a blowout. Drain holes can be added to parts directly in PreForm to help drain cups or hollow parts. 

The technology powering Form 4 Series printers makes it easier than ever to go from design to print. Help ensure print success by following the detailed design guidelines in the Form 4 design guide.

Formlabs offers extensive support documentation for all of our professional 3D printers. If you are looking for additional information, please check out our support website.