Fast Instructions for Use (IFU) & Printing Parameters for Form4 DLP printers

This document provides fast, visual and practical guidance for the use of 3Dresyns® photopolymer resin systems on Formlabs Form4 Open Material Mode workflows.

This Fast IFU for Form4 printers is intended as a visual reference and workflow aid and complements the official:

• Instructions for Use (IFU) & Printing Parameters for DLP & LCD printers
• Fast Instructions for Use (IFU) & Printing Parameters for DLP & LCD printers
• Instructions for Use (IFU) & Printing Parameters for Form4 DLP printers

This Fast IFU does not replace the official IFU and does not define validated or universal processing conditions.

1) Purpose of this Fast IFU

The purpose of this Fast IFU is to:

• provide practical guidance for Form4 Open Material workflows,
• support faster onboarding and troubleshooting,
• give a practical route for selecting starting print settings before deeper optimisation,
• introduce a fast CRT logic for rapid calibration.

Images, screenshots and examples shown in this document are illustrative only. User interfaces, firmware versions and available options may change over time.

2) Scope and limitations

This Fast IFU applies to selected Formlabs Form4 Open Material Mode workflows.

Performance, print quality and material behaviour depend on the complete material–printer–process–post-processing system, including:

• resin formulation and version,
• selected exposure behaviour,
• target layer thickness,
• temperature and viscosity,
• post-processing workflow,
• environmental conditions.

3Dresyns does not control Formlabs hardware, firmware updates, user-interface changes or proprietary exposure algorithms.

Users remain responsible for:

• validating final settings for their intended application,
• verifying resin compatibility with their workflow,
• following the official IFU for all critical processing steps.

3) Relationship to official Instructions for Use

In case of discrepancy between this Fast IFU and any official Instructions for Use (IFU), the official IFU always prevails.

This Fast IFU is provided for convenience, illustration and workflow orientation only.

4) Standard starting settings for Form4

These are typical starting points for Form4 Open Material workflows and must be validated experimentally for each resin system and application.

• Z layer thickness: typically 0.050 mm
• Operating temperature: typically 30–40 °C
• Resin start temperature: typically ~30–35 °C
• Exposure behaviour: must be validated experimentally using CRT logic
• Support strategy: use conservative and robust supports during first validation
• Peel and squish behaviour: start conservatively before increasing print speed

Example of a conservative Form4 Open Material starting framework. Conservative starting values are generally recommended during the first validation cycles.

Interpretation rule: these are not fixed recipes. They are a rapid starting framework from which the user performs structured CRT-based optimisation.

5) Why Form4 settings are workflow-dependent

• Resin viscosity changes with temperature.
• Filled systems may behave differently during recoating and separation.
• Different geometries require different support strategies.
• Exposure response depends on resin chemistry and optical conditions.
• Tank adhesion may increase significantly if exposure becomes excessive.

As a result, generic settings are only practical approximations and cannot guarantee reproducible results across printers or workflows.

Example of Form4 Open Material workflow configuration. Stable exposure behaviour and reliable adhesion should be prioritized before advanced optimization.

6) Fast CRT logic for Form4

The quickest structured way to identify a useful starting exposure is to use a fast CRT.

Recommended fast CRT starting points: 5 s, 10 s and 15 s.

• Measure cured thickness at 5 s, 10 s and 15 s.
• Evaluate cured thickness and green-state strength.
• Add 1–2 extra points only in the relevant interval.

Filled or slower systems may require additional measurements beyond 15–20 s.

7) Parameter interpretation strategy

During first implementation it is generally recommended to begin with:

• no XY compensation,
• no Z compensation,
• no dimensional correction offsets,
• no aggressive software compensation strategies.

Users should first stabilize:

• exposure behaviour,
• adhesion reliability,
• green-state strength,
• peeling behaviour,
• recoating stability.

Only after stable printing behaviour is obtained should dimensional compensation be introduced if necessary.

Example of dimensional compensation settings. Initial workflow optimization is generally recommended without dimensional correction offsets.

8) Temperature, viscosity and separation behaviour

Temperature strongly affects viscosity, resin flow and peeling behaviour.

For viscous systems, controlled moderate heating may:

• reduce viscosity,
• improve resin flow,
• improve recoating consistency,
• reduce peeling force.

As a practical guideline, viscous materials are often easier to process at approximately 30–40 °C.

Important note: some thermoplastic-like or softer materials may deform if very thin geometries are printed at excessively high temperatures.

Thin geometries combined with elevated temperatures may promote:

• thermal deformation,
• warpage,
• loss of dimensional stability.

Additional practical note: even relatively low-viscosity resins may still generate excessive adhesion to the tank if exposure becomes too high.

Over-curing may increase:

• tank adhesion,
• peeling force,
• risk of print failure.

Example of peel, squish and separation-related settings. Conservative values are generally recommended for difficult, filled or peel-sensitive systems.

Example of thermal management settings. Moderate controlled heating may improve resin flow and reduce separation force for viscous systems.

9) Quick validation prints

• Download 3Dtest1 calibration STL file
• Download 3Dtest2 calibration STL file

9.1 Calibration step 1 — Print 3Dtest1

This first fast test evaluates:

• general printability,
• adhesion behaviour,
• XY resolution,
• appropriateness of the selected exposure.

9.2 Calibration step 2 — Print 3Dtest2

This second test evaluates:

• support performance,
• XYZ printability,
• Z-axis dimensional accuracy.

Example of additional advanced workflow settings available in Form4 Open Material Mode. Intermediate or conservative values are generally recommended during early optimization.

10) Interpreting failures (quick fixes)

• Part detached from build platform: increase adhesion behaviour and/or exposure
• Part too soft or incomplete: under-cured → increase exposure
• Part too brittle or excessively adhered: over-cured → reduce exposure
• Poor detail resolution: reduce over-curing and re-check CRT
• Inconsistent behaviour: verify resin homogenization and temperature stability

11) Cleaning and post-processing

Final part performance depends not only on printing settings, but also on cleaning, drying and post-curing.

• Wash using the validated cleaning workflow.
• Ensure parts are fully dried before final post-curing.
• Follow any material-specific IFU where applicable.

Drying before post-curing is mandatory.

12) Advanced optimisation notes

Advanced workflow optimisation on Form4 systems may involve:

• temperature optimisation,
• support optimisation,
• exposure refinement,
• orientation strategy,
• peel and separation optimisation.

Users implementing advanced optimisation strategies remain responsible for documenting final settings and validating performance for their intended application.

13) Governing principle

This Fast IFU provides practical guidance only.

Final material performance depends on the complete material–printer–process–post-processing chain and must be validated by the user for the intended application.

14) Contact

For calibration support, workflow optimisation or technical support, contact info@3dresyns.com.