Formlabs stereolithography (SLA) 3D printers and post-processing units offer powerful manufacturing capabilities in a user-friendly design and size. Unlike many other stereolithography solutions available, Formlabs SLA systems typically don't need intricate infrastructure, extensive ventilation, or specialized power requirements.

Formlabs SLA printers and post-processing accessories are designed with the often-overlooked dangers of low-cost resin printers in mind. We take the potential hazards of chemicals like ACMO seriously, and maintain a firm commitment to user safety. Our innovative features, like spill-minimizing resin cartridges, ACMO-free resins, and comprehensive support systems designed to create a safer, more reliable printing experience differentiate us from the competition.

SLA 3D printing offers incredible precision and detail, but it's crucial to prioritize a safe workspace when working with resins and solvents. This guide will walk you through the essential steps to create a safe SLA print area, drawing on expert recommendations from Formlabs.

How do I prepare my workspace for SLA printing?

Designate a specific area for SLA printing, separate from other activities, to ensure a safer and more organized workspace. Make sure to set up your Formlabs printer and post-processing tools on a stable, level surface. This minimizes the risk of accidental spills or contamination in other areas.

While Formlabs resins don’t require special ventilation due to the lack of volatile chemicals like ACMO, you should always operate your Formlabs SLA printer and Form Wash in a space where air circulates freely to prevent the buildup of fumes and vapors. Follow code guidelines, such as those defined by the International Building Code (ICC), to ensure your space meets local requirements for a well-ventilated occupied space. Printers should not be operated in closed off, unventilated spaces such as closets or small storage rooms like a janitorial supply closet.

Formlabs recommends using its SLA products in room equipped with HVAC systems providing at least three full air exchanges per hour. If needed, you can increase the air exchanges per hour without having to change the HVAC systems in place by adding exhaust fans in windows.

How do I ensure safety during setup?

Desktop machines in the Formlabs SLA ecosystem, such as the Form 4, Form Wash, and Form Cure, can be safely set up by a single person. When setting up larger Formlabs SLA devices, such as the Form 4L, Form Wash L, and Form Cure L, always work with a partner and use the included lifting straps or carrying sling to move the machine.

Do not lift or reposition your machine:

• By the cover or any other movable part of the device
• When it is connected to a power source
• When it is connected to an Ethernet or USB cable

Are there hot surfaces that I should be mindful of?

For optimal printing, Formlabs SLA printers maintain the resin at approximately 35 °C (95 °F) while in use. Some Formlabs SLA printers, such as the Form 2 and Form 4, heat the resin with a resistive heating element under the resin tank. This heater can become very hot during the printing process. If you remove the resin tank immediately after printing, do not touch the areas under the tank until they reach room temperature. Other printers, such as the Form 3 and Form 3L, use air heaters to bring the resin to its target temperature and do not pose a burn hazard.

• The Form Cure and Form Cure L contain heaters to help ensure that parts reach the material’s optimum properties after post-curing. While the heaters and fan designs limit overheating and the heaters are insulated to contain heat, surfaces of the machines and printed parts may be hot during and after use. Take care when removing post-cured parts from the machine.
  • Form Cure (1st Generation) only: The turntable can remain hot during and after a cure cycle. Always allow the turntable to cool completely before touching or cleaning.
• The Fast Cure contains banks of LEDs to post-cure parts. These LEDs generate heat during use, so surfaces of the Fast Cure and printed parts may be hot during and after use. Use thermal-insulating gloves safe to at least 160 °C (320 °F) when removing a hot turntable tray or post-cured printed part.

Has Formlabs performed any internal air quality tests?

Formlabs regularly performs internal air quality testing to ensure compliance with regulatory standards and occupational exposure limits for the chemicals used in our workplace.

Air quality evaluations are conducted under the following circumstances:

• When new chemicals with hazardous properties are procured
• When new job tasks with anticipated chemical exposure are introduced
• When changes to existing job tasks may impact employee chemical exposure
• When major changes to lab layout, equipment, or processes occur
• Periodically, to ensure our data remains current
• When qualitative reports indicate a potential issue

Formlabs air quality assessments are based on direct measurements. We perform both room sampling and employee sampling as part of our assessment process:

• Room sampling helps us understand potential exposure levels in a specific area over the course of a full day.
• Employee sampling reflects real-world exposure during typical working conditions and job specific activities.

Collecting quantitative data from both room and employee sampling allows us to make informed decisions regarding site policies and control measures. Results are compared against regulatory limits as defined in Section 8 of each chemical’s Safety Data Sheet (SDS).

At this time, all Formlabs facilities remain below OSHA exposure limits for the chemicals we use. Accordingly, our respirator policy for printing tasks is classified as voluntary use.

How should I maintain my workspace?

Regular cleaning is essential; promptly clean up any resin spills and solvent residue, following all local regulations for the disposal of resin waste and used solvents.

Perform regular maintenance on your Formlabs printer and Form Wash according to Formlabs instructions to ensure your equipment is functioning as expected. This helps ensure safe operation and minimizes the risk of accidents and spills.

By following these guidelines, you can create a safe and efficient SLA print area, ensuring the well-being of yourself and those around you. Consult the Formlabs support site for all product documentation.

What safety features do Formlabs resin printers offer?

Formlabs resin printers have several features that help to mitigate possible working hazards. For more information, consult the printer’s manual. Some of the features that help to ensure a safe user experience include:

• Interlocks prevent the laser from powering on while the printer cover is open.
• Users may view the print job through the translucent printer cover, allowing for monitoring of the print enclosure.

What safety features do other machines in the Formlabs resin ecosystem offer?

Formlabs offers other machines as part of the Formlabs resin ecosystem, such as the Form Wash and Form Cure. These machines have several features that help to mitigate possible working hazards. For more information, consult the manual for your device. Some of the features that help to ensure a safe user experience include:

• Formlabs automated part washing machines, including the Form Wash and Form Wash L, have double lids that keep the solvent bath covered during and between wash cycles.

• Formlabs post-curing chambers, including the Form Cure, Form Cure L, and Fast Cure, contain interlocks that prevent their motors, LEDs, and heaters from powering on while the cover or door is open.

Is the light source used by Formlabs resin printers safe?

Formlabs Form 1+, Form 2, Form 3 generation, and Form 3L generation printers are Class 1 Laser Devices, the safest classification of laser devices, despite using Class 3B lasers, which can cause injury if exposed directly to a person’s eyes or skin. Form 4 and Form 4L generation printers use a set of 405 nm LEDs to cure liquid resin rather than a laser.

These laser-based Formlabs SLA printers maintain their safe, Class 1 designation because the laser is entirely contained within the printer without a means of escape. Interlocks ensure that lasing does not occur while a user is accessing the machine. If these systems are tampered with or fail, there is a risk of exposure to Class 3B laser light. Due to the inability of users to reach the path of the laser during normal operation of the printer, the device is categorized as a Class 1 Laser Product.

Handle solvents and resins with care, adhering to safety guidelines, and maintain a clean and organized workspace. Prioritize ventilation to minimize exposure to fumes and vapors, and always wear appropriate personal protective equipment (PPE), including gloves, eye protection, and protective clothing. Always consult the Safety Data Sheet (SDS) for specific safety information. Recommendations for safe handling of resin and solvents for the Form Wash, such as TPM and IPA, are available through the Formlabs support site. PDFs of the SDS for each of our materials are available through our Materials Catalog.

Are there safety concerns associated with cleaning using solvents such as IPA or TPM?

Handle solvents with gloves in a well-ventilated area and keep away from heat, sparks, and open flames. Solvents such as isopropyl alcohol evaporate rapidly, and their vapors are flammable, so keep bottles closed whenever possible.

When handling flammable solvents, always consult the safety data sheet (SDS) from the supplier as the primary source of information.

What personal protective equipment (PPE) should I wear?

Always wear non-reactive nitrile or neoprene gloves to prevent skin contact with liquid resin and wash solvents. If your skin is exposed to resin or solvent, promptly wash the affected area with soap and water.

Safety glasses are recommended, particularly during post-processing, to protect your eyes from resin, dust, support fragments, or other debris. Suitable protective clothing, such as long-sleeved shirts and long pants, is recommended, and work clothing should be routinely washed.

Respiratory protection, such as an N95 respirator or better, is only necessary when exceeding exposure limit values listed in the SDS or if your workspace has insufficient ventilation. You may also want to wear respiratory protection when sanding your printed parts. You can also wet sand to minimize dust.