The Align build platform calibration tool is an advanced troubleshooting feature on Form Studio 1 printers. Align your build platform and Light Processing Unit after replacing the LPU to help with model adherence issues across the build platform.

The Form Studio 1 printing process requires the build platform and the LPU surface to be parallel. Deviations may result in model adherence issues and print failures. While the printer is pre-calibrated for build platform parallelism, users can calibrate individual build platforms to improve the printer’s dimensional accuracy and increase print success.

Formlabs recommends using Align build platform in the following situations: 

• Overcompression: A print defect in which reduced space between the build platform and resin tank causes the initial layers to be very thin. The rest of the part prints, but the initial layers are flattened and may be difficult to remove from the build platform.
• Non-adherence: A print defect in which prints are either partially or completely detached from the build platform. This occurs when the initial layers of a print fail to adhere to the build platform.
• After replacing the LPU

Tools required:

• Alignment shims (4x, located in the tool caddy)
• 4 mm hex key (located in the tool caddy)

To align the build platform:

1. Update the printer’s firmware.
2. Ensure that the printer is not running a print job and is currently Idle.
3. Put on a pair of clean nitrile gloves.
4. Remove the build platform from the printer. 
5. Clean the build platform so that it is entirely free of resin.
6. Cover the resin tank with its lid. 
7. Remove the resin tank from the printer.
8. Remove the resin cartridge from the printer.
9. Close the cover.
10. Tap the gear icon on the printer’s touchscreen. The Settings screen appears. Tap Tools > Align build platform. 

13. Insert a clean build platform. Make sure it is completely free of resin. The build platform will make contact with the Light Processing Unit during alignment, and any resin residue may cause contamination or damage.
    • If you are using a Form Studio 1 Build Platform Flex, make sure that the print surface is properly installed on the build platform body.

15. Close the cover. The printer lowers the build platform to lie flat on the LPU texture. 
16. Open the cover. 
17. With one hand pressing the build platform to lie completely flat on the LPU texture, use the 4 mm hex key to tighten the alignment screws over two passes. Ensure that the screws are secure.
18. Close the cover. The printer calibrates the Z-axis limit.
19. Once the calibration is complete, return the alignment shims to the tool caddy and reinsert the resin tank and cartridge.
20. Print small models to test the change.