Alloys
Additive manufacturing (AM), widely known as 3D printing, continues to transform product development and manufacturing. As more industries rely on high-quality 3D printing, distributors and resellers need solutions that deliver consistent, dependable results. While many 3D printers have advanced in speed and capability, reliability remains a common challenge—making proven-performance printers more valuable than ever.
Formlabs Form 4 Performance Overview
The Formlabs Form 4 sets a new standard for reliability in stereolithography (SLA) 3D printing. Designed to reduce peel forces and maintain a stable printing environment, the Form 4 integrates advanced automated diagnostics, monitoring tools, and performance safeguards. These features make it an excellent fit for users who require dependable, repeatable results in professional or mission-critical workflows.
In an independent global study, the Form 4 achieved a 98.7% print success rate, positioning it among the most reliable SLA 3D printers available today. Its consistent output helps businesses significantly reduce operating costs, labour hours, and reprint cycles.
Comprehensive SLA 3D Printer Reliability Testing
A global product-testing leader conducted a comprehensive evaluation comparing the reliability and repeatability of the following printers:
Testing Methodology
The objective was to evaluate print success rates and repeatability of parts produced by select stereolithography (SLA) 3D printers, including Formlabs Form 4, Form 3+, and two other low-cost resin 3D printers.
The tests followed a standardized operating procedure (SOP) defined by Formlabs to ensure fair and consistent evaluation across different printers. Key elements of the SOP included:
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Weekly inspection of printer components.
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Pre-filling resin tanks where automatic dispensing was unavailable.
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Quality checks before and after each print.
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Consistent use of standard grey resin and manufacturer-recommended settings.
A total of 225 prints were conducted on each printer type, with 15 different 3D models printed three times on five separate printers for each brand.
Print Success Rates
| Printer | Print Success Rate | Failure Rate | Dead on Arrival Units | Lost Hours Due to Failures |
| Formlabs Form 4 | 98.7% | 1.3% | 0 | 9 hours |
| Formlabs Form 3+ | 98.7% | 1.3% | 0 | 17 hours |
| Benchmark A | 86.2% | 13.8% | 0 | >100 hours |
| Benchmark B | 74.7% | 25.3% | 2 | >250 hours |
The Formlabs Form 4 stood out with a remarkable 98.7% print success rate, showcasing 10x to 20x better reliability compared to the benchmark printers.
Key Failure Modes
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Form 4 and Form 3+: Occasional missing chunks and print stoppages.
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Benchmark A: Issues such as non-adherence, delamination, and cracking.
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Benchmark B: Severe problems, including homing failures, LED module failures, and multiple LCD failures.
Notably, two printers from Benchmark B arrived non-functional and required replacement before testing could proceed.
Why Reliability Matters for Your Business
High reliability directly impacts operating efficiency. The Form 4’s performance helps businesses:
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Reduce resin and consumable waste
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Minimise printer downtime
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Lower labour hours spent on troubleshooting
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Improve production scheduling accuracy
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Deliver better results to end clients
For distributors and resellers, offering reliable devices leads to fewer support tickets, happier customers, and long-term trust.
Low-cost printers may appeal to hobbyists, but businesses working in engineering, product development, healthcare, and manufacturing require printers that perform consistently. The Formlabs Form 4 addresses this need through proven reliability and predictable print outcomes.
Learn More
To explore the full methodology and complete study findings, download the detailed white paper.
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