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

This document provides printer-specific guidance for using 3Dresyns® photopolymer resin systems on Formlabs Form4 Open Material Mode workflows.

This page is a printer-specific supplement to the general Instructions for Use (IFU) & Printing Parameters for DLP & LCD printers and must be used together with it. It does not replace the general IFU and applies only to defined Form4 Open Material workflows and configurations.

1) Scope, limitations and responsibilities

Scope of application

• Applies to 3Dresyns® photopolymer resin systems processed using Formlabs Form4 Open Material Mode.
• Applies to workflows where the user defines or modifies exposure and process parameters manually.
• Applies only to compatible vat photopolymerization workflows.

Limitations

• This document provides reference workflows and qualified calibration methodology, but does not replace user-side validation.
• 3Dresyns does not control Formlabs hardware, firmware revisions, optical calibration, software updates or proprietary exposure algorithms.
• User interfaces, parameter names and available controls may change depending on firmware and software versions.
• Application-specific validation, regulatory compliance and final product qualification remain the responsibility of the user or legal manufacturer.

2) Relationship to official Instructions for Use

This Form4 IFU must always be used together with:

• Instructions for Use (IFU) & Printing Parameters for DLP & LCD printers
• any material-specific IFU where applicable,
• any application-specific IFU where applicable.

In case of discrepancy, the official IFU always prevails.

3) Material system and resin homogenization

3Dresyns® photopolymer resins are supplied as system-based materials that may exist in multiple viscosities, colours, filler contents and functional configurations.

Before printing:

• verify the resin version and lot number,
• verify compatibility with Form4 Open Material workflows,
• verify associated TDS and IFU documentation.

Resin homogenization before printing

Proper resin homogenization is part of process control.

The required homogenization methodology depends strongly on:

• filler loading,
• particle density,
• sedimentation tendency,
• resin viscosity,
• functional powder content.

For simple low-viscosity or non-technical systems where no significant sedimentation is present, manual homogenization by hand shaking may be sufficient.

However, for more technical systems containing:

• high powder loading,
• bio-based powders,
• ceramic particles,
• metallic particles,
• functional fillers,
• sedimentable additives,
• high-density pigments,
• high-viscosity components,
• fibres or reinforcing particles.

manual hand shaking may become insufficient to achieve complete homogenization.

In these cases, the use of a conventional laboratory mixer, mechanical stirrer or overhead laboratory mixing system is strongly recommended.

The objective is to obtain:

• uniform additive distribution,
• stable viscosity,
• consistent curing behaviour,
• reproducible printing performance.

Incomplete homogenization may lead to:

• sedimentation gradients,
• unstable curing response,
• variable viscosity,
• print failure,
• dimensional inconsistency.

Where significant sedimentation tendency exists, periodic re-homogenization during long printing sessions may also be necessary.

4) Record keeping (minimum)

For traceability and reproducibility, record at minimum:

• resin name, version, additives and lot number,
• Form4 firmware and software version,
• selected Open Material profile,
• layer thickness,
• exposure and process settings,
• temperature settings,
• orientation and support strategy,
• washing and post-curing workflow,
• ambient conditions.

5) Reference starting parameters for Form4

The following values are practical starting points only and must be validated experimentally for each resin system, geometry and workflow.

Example of a conservative Form4 Open Material starting framework. Initial calibration is generally recommended using moderate temperatures, conservative process behaviour and stable support strategies before introducing advanced optimization or speed-oriented settings.

Screenshots are illustrative only. User interface, parameter names and available controls may change depending on firmware and software versions.

Interpretation rule: these are not validated universal settings. They are intended only as a structured starting framework for CRT-based optimization on Form4 systems.

6) Why Form4 settings are workflow-dependent

Form4 Open Material workflows remain strongly dependent on:

• real irradiance and optical behaviour,
• firmware version,
• resin viscosity and temperature,
• target layer thickness,
• geometry and support strategy,
• tank condition,
• resin homogeneity.

Generic exposure settings therefore cannot guarantee reproducible results across printers, firmware versions or workflows.

7) Fast CRT logic for Form4 workflows

The Curing Rate Table (CRT) remains the most practical method for selecting exposure settings based on the real curing behaviour of the resin on the target Form4 system.

For rapid implementation:

• start with a fast CRT using 5 s, 10 s and 15 s,
• evaluate cured thickness and green strength,
• add 1–2 extra points only in the relevant interval.

Highly filled or slower systems may require additional points beyond 15–20 s.

8) Form4 Open Material workflow

During initial workflow calibration:

• start with conservative process settings,
• avoid aggressive separation behaviour,
• prioritize stable adhesion and green strength before speed optimization,
• validate exposure experimentally.

The most important user-controlled variables are typically:

• layer thickness,
• exposure energy,
• temperature,
• peel behaviour,
• squish/recoating behaviour,
• support strategy.

Example of Form4 Open Material workflow configuration. Users should initially prioritize exposure stability, adhesion reliability and reproducible recoating behaviour before optimizing dimensional compensation or aggressive process parameters.

9) Form4 parameter interpretation strategy

During initial calibration and workflow stabilization, it is strongly recommended to begin with:

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

The initial objective should be to stabilize the fundamental printing behaviour of the material–printer system before introducing secondary compensation logic.

Users should first optimize:

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

Only after obtaining stable and reproducible printing behaviour should dimensional compensation strategies be introduced if necessary.

Overuse of software compensation during early calibration may mask the real origin of printing problems and complicate process optimization.

Conservative versus aggressive settings

During first implementation, conservative settings are generally preferred over aggressive high-speed configurations.

Where the interface allows interval-based values, intermediate or conservative values are typically recommended during the first validation cycles.

After successful stabilization, the workflow may then be progressively optimized for:

• higher speed,
• higher resolution,
• reduced peel force,
• improved dimensional precision,
• improved surface quality.

Users implementing advanced optimization strategies remain responsible for validating final settings under their real workflow conditions.

Example of dimensional compensation and correction settings. During initial workflow stabilization, it is generally recommended to begin without XY or Z compensation and optimize the core material–printer behaviour first.

10) Exposure and layer strategy

As a general practical rule:

• under-cured: soft, weak or incomplete parts → increase exposure
• over-cured: excessive adhesion, brittleness or detail loss → reduce exposure

Select exposure using CRT logic and the appropriate cure-thickness factor.

• Fast or brittle systems: typically closer to 1.0–1.2× target layer thickness
• Softer or peel-sensitive systems: typically closer to 1.3–1.5×

Important practical note: even relatively low-viscosity resins may still generate excessive adhesion to the tank or release interface if the selected exposure becomes too high.

Over-curing may significantly increase:

• tank adhesion,
• peeling force,
• mechanical stress during separation,
• risk of print failure or part damage.

Exposure optimization must therefore always be evaluated together with temperature, viscosity and separation behaviour.

11) Peel, squish and separation behaviour

Form4 workflows may be sensitive to:

• peel force,
• resin refill dynamics,
• recoating viscosity,
• support geometry.

For difficult or filled systems:

• start conservatively,
• reduce aggressive motion behaviour,
• increase stabilization where necessary,
• prioritize stable green strength before optimization for speed.

Example of peel, squish and separation-related settings. Conservative values are generally recommended during first implementation, especially for filled, viscous or peel-sensitive systems.

12) Temperature, viscosity and thermomechanical behaviour

Temperature strongly affects resin viscosity, recoating dynamics, separation behaviour and dimensional stability.

For viscous systems, increasing resin temperature may significantly reduce viscosity, improve resin flow and reduce separation or peeling forces during printing.

As a practical engineering guideline, viscous materials are often easier to process at approximately 30–40 °C, depending on the resin system and workflow.

Potential benefits of controlled moderate heating may include:

• reduced viscosity,
• improved resin flow and recoating behaviour,
• reduced peeling or separation force,
• improved refill consistency,
• more stable printing of filled systems.

However, thermal management must remain controlled and validated because excessive temperature may also affect curing kinetics, dimensional stability and green-state mechanical behaviour.

Important thermomechanical note: some thermoplastic-like or thermomechanically softer materials may deform during printing or post-processing if the printed geometry is very thin and the working temperature becomes excessively high.

Thin geometries, low structural rigidity and elevated printing temperatures may promote:

• thermal deformation,
• warpage,
• dimensional instability,
• loss of geometric accuracy.

For these systems, the user may need to balance:

• reduced viscosity and lower peeling force,
• versus thermal dimensional stability of the printed geometry.

Example of thermal management and temperature-related settings. Moderate controlled heating may improve resin flow and reduce peeling force for viscous systems, although excessive temperature may also promote deformation in thin or thermomechanically soft geometries.

Example of additional advanced workflow settings available in Form4 Open Material Mode. Intermediate or conservative values are generally recommended during early validation cycles before implementing aggressive optimization strategies.

13) Validation using 3DTEST1 and 3DTEST2

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

3Dtest1

Used to evaluate:

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

3Dtest2

Used to evaluate:

• support behaviour,
• XYZ printability,
• Z-axis dimensional accuracy,
• supported workflow stability.

14) Troubleshooting logic

• Complete detachment: increase initial adhesion behaviour and/or exposure
• Soft or incomplete parts: increase standard exposure
• Excessive brittleness or excessive adhesion: reduce exposure
• Poor detail resolution: reduce over-curing and re-evaluate CRT
• Inconsistent behaviour: verify resin homogenization and temperature stability

15) Cleaning and post-processing

Cleaning and post-processing remain critical process variables.

Final material behaviour depends strongly on:

• washing chemistry,
• washing time,
• drying quality,
• post-curing wavelength,
• post-curing power,
• post-curing time and temperature.

Drying before post-curing is mandatory.

Washed parts must be fully dried before final post-curing.

16) Advanced Form4 optimization considerations

Advanced optimization may involve:

• temperature optimization,
• support optimization,
• orientation strategy,
• exposure refinement,
• peel/separation optimization,
• viscosity management.

Users implementing advanced optimization remain responsible for validation, traceability and application qualification.

17) Governing principle

Form4 Open Material workflows provide a flexible engineering framework, not a universal validated preset system.

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

18) Need technical support?

For printer qualification, CRT definition, workflow optimization or advanced technical support, contact info@3dresyns.com.