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Replacing the Form 3L tensioner motor

The Form 3L has a tensioner motor that tightens the flexible film on a resin tank for printing. A malfunctioning tensioner motor may prevent the printer from printing properly. The motor is located at the back of the printer and can be accessed by removing the shell.

Use this guide to replace the Form 3L tensioner motor.

Required Supplies:

Formlabs:

Replacement tensioner motor

Third-party:

NYE Rheolube 362HF or similar
3 mm hex driver
2.5 mm hex driver
T10 Torx driver
T8 Torx driver
Nitrile gloves
Flashlight (optional)
Masking tape (optional)

Estimated time: 30 minutes

Danger:

Read and follow all safety instructions and warnings in the operator manual. Replacement with incorrect parts can lead to burns, shock, fire, or explosion. Dispose of all parts in accordance with local regulations.

Preparing the workspace

Overview: Prepare the Form 3L and a dust-free workspace for replacing the tensioner motor.

Step 1: Remove the build platform

Remove the build platform first to avoid dripping resin into the printer cavity.

Step 2: Remove the resin cartridges

Remove the resin cartridges and close the vent caps to prevent resin from dripping off the bite valves and into the printer.

Step 3: Remove and store the resin tank

Remove the resin tank, place it in the resin tank case, and cover it with its lid. Set the case and tank aside on a clean, flat surface.

Notice:

Wear gloves and hold the resin tank by the tank grips on either side to avoid contamination or damage to the underside of the tank.

Step 4: Prepare the workspace

Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust. Prepare additional space for storing the rear panel of the printer during maintenance.

Step 5: Unplug the printer

Disconnect the power cable before continuing with maintenance. Do not perform maintenance on the printer while it is connected to power. Wait five minutes after disconnecting the printer from power before proceeding.

Danger:

Performing maintenance on the printer while it is plugged in increases the risk of electric shock. Never remove the back panel of the printer while the printer is plugged in. Never reconnect the printer to power while the back panel is uninstalled.

Step 6: Clean the printer cavity

Warning:

Resin may cause skin irritation or an allergic skin reaction. Wear gloves when handling liquid resin or resin-coated surfaces. Wash skin with plenty of soap and water.

Open the printer cover. Check inside the printer cavity to ensure that no resin has pooled on the printer floor. Clean any resin inside the printer cavity with paper towels. Dampen the paper towels with isopropyl alcohol if necessary to fully remove the resin.

Danger:

IPA is flammable and presents a fire hazard. Keep containers closed, and keep out of the reach of children.

Removing the rear shell

Overview: Unscrew and remove the rear shell of the printer.

Notice:

The Form 3L contains sensitive electronic components. Ground yourself before touching any electronics in the printer by using a grounding strap or touching a grounded piece of metal.

Step 1: Remove the Wi-Fi antenna nut

Unscrew and remove the nut from the base of the Wi-Fi connector. The Wi-Fi connector is attached to the printer’s motherboard and remains in place when the rear shell is removed.

Step 2: Remove the rear shell screws

Use a T10 or T8 Torx driver to loosen and remove the 21 screws on the rear shell. Early models may use all T8 screws, while later models use all T10 screws. Start at the bottom of the panel and work your way up to the top.

Step 3: Remove the rear shell

Remove the rear shell by pulling it away from the printer. There are five pins that hold the panel in place, so it may require moderate force to separate from the printer. Be careful not to damage the rear fan cable, which is still attached to the rear shell. Lay the rear shell down next to the printer.

Step 4: Disconnect the rear fan

Disconnect the rear fan cable harness by gripping the plugs and gently pulling them away from each other. Do not pull on the wires themselves.

Removing the tray

Overview: Unplug the tensioner motor cable and remove the plastic tray to gain access to the tensioner assembly.

Step 1: Unplug the tensioner motor cable

Locate the tensioner motor at the rear of the printer and unplug the connector. Press down on the tab of the latching mechanism to release.

Step 2: Remove the plastic tray

Locate and remove the plastic tray that sits on top of the tensioner assembly.

Step 3: Disengage the tensioner motor

Locate the tensioner motor tool underneath the plastic tray. Use the tool to turn the exposed spur gear counterclockwise until resistance is met to fully disengage the tank tensioner. Place the tensioner motor tool in the plastic tray for reinstallation at the end of the procedure.

Removing the tensioner motor

Overview: Remove the shroud before removing the tensioner mount screws.

Step 1: Remove the shroud

A plastic retention pin secures the shroud around the motor. Pull with firm, sustained force to disengage the retention pin before fully pulling the pin out for removal. Hold onto the retention pin for reinstallation of the shroud at the end of the procedure.

Step 2: Hold back the shroud

Fold or tape the shroud away from the working area with masking tape.

Step 3: Remove the tensioner motor retention screws

Five 3 mm hex screws are at the top of the mounting plate to hold the assembly in place. Remove all five screws from the tensioner motor mounting plate using a 3 mm hex driver. Hold onto the screws for reinstallation at the end of the procedure.

Step 4: Remove the tensioner motor

Pull the motor downward to complete the removal of the tensioner motor.

Reinstalling the tensioner motor

Overview: Grease the gear, then install the new tensioner motor.

Step 1: Grease the spur gear

Grease the spur gear on the new tensioner motor.

Step 2: Install the tensioner motor

Note the orientation of the tensioner motor above for correct mounting and installation. Ensure that the tensioner motor mounting plate does not pinch any cables. Thread the spur gear into its place on the printer. Secure the tensioner motor with the five 3 mm hex screws.

Step 3: Reinstall the shroud

Resecure the plastic shroud using the plastic retention pin.

Step 4: Reinstall the plastic tray

Secure the tensioner motor tool underneath the plastic tray. Slide the plastic tray back into place above the tensioner motor.

Step 5: Reconnect the cable

Reconnect the tensioner cable. The latch gives an audible click when secured.

Step 6: Connect the rear fan

Lay the rear shell down behind the printer. Reconnect the two ends of the rear fan cable.

Step 7: Replace the rear shell

Place the rear shell back onto the printer, taking care to align the five pins on the shell with their respective holes. Press it towards the front of the printer to ensure that it fully seats in place. There should be no gaps between the rear shell and the side or bottom shells.

Step 8: Secure the rear shell

Using a T8 or T10 Torx driver, screw the 21 screws into the rear of the printer.

Finalizing the repair

Overview: After installing the new tensioner motor, insert a tank into the printer and start a print to see if it is tensioned properly.

Step 1: Plug in the printer

Plug in and power on the printer. The printer's Home screen should display with no errors.

Step 2: Test the tensioner

Insert a tank into the printer. Start a print to ensure that the film is tensioned properly. Contact Formlabs Support or your authorized reseller to share the results of the procedure.