Additive manufacturing (AM), more commonly known as 3D printing, has become a key tool in accelerating product development and manufacturing across various industries. As demand for high-quality solutions grows, offering reliable products to clients becomes critical for those in the distribution and sales channel. Despite significant advancements, many 3D printers still face challenges with consistent performance.
Formlabs Form 4
The Formlabs Form 4 is setting new benchmarks in the world of additive manufacturing with its unparalleled reliability and performance. Engineered to minimize peel forces and ensure consistent printing environments, the Form 4 offers advanced automated diagnostics and monitoring features. Professionals seeking dependable printing solutions will find the Form 4 an essential tool for mission-critical operations.
In a recent independent study, the Form 4 achieved a remarkable 98.7% print success rate, making it one of the most reliable SLA 3D printers available today. This printer's exceptional performance dramatically reduces operational costs and labor hours, making it a standout choice for businesses.
Comprehensive Testing and Results
To demonstrate its reliability, a series of performance tests were conducted by an independent global leader in product testing. 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.
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
Reliable printers like Formlabs Form 4 can significantly reduce operational costs by minimizing resin and consumable waste, labor hours, and machine downtime. For businesses in the sales channel, this translates to delivering dependable solutions to clients, fewer support requests, and stronger customer relationships.
Conversely, printers with high failure rates lead to increased troubleshooting, cleaning failed prints, and rescheduling production timelines—all of which impact customer satisfaction.
The demand for reliable and accurate 3D printers continues to grow, particularly among professionals who rely on additive manufacturing for mission-critical applications. While low-cost printers may suffice for hobbyist use, businesses serving professional markets benefit greatly from offering reliable solutions like Formlabs Form 4.
To learn more about the comprehensive testing parameters and detailed results, download the white paper.
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