© 2015 Construction Industry Solutions

HOW TO...

Use the Form 1+ 3D printer

Date:

23 Apr 2015

Document Version:

2

These notes are published as guidelines only.

This “How to…” Guide may contain recommendations about configuration changes. Your configuration will almost certainly vary from the examples given in this document. Any

configuration changes should always be applied to a separate non-live environment first and tested to prove that the features work as you require. Should you have any difficulties with this

please contact the COINS Support Centre or your account representative to arrange for some COINS consultancy.

Please note that you should not expect the Support team to conduct configuration changes for

you.

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Contents

1 How to use this guide ................................................................................................ 4

2 Basic safety ............................................................................................................... 5

2.1 Laser .................................................................................................................................... 5

2.2 Resin .................................................................................................................................... 5

2.3 Isopropyl Alcohol (IPA) ........................................................................................................ 5

2.4 Tools .................................................................................................................................... 5

3 Design rules and PreForm .......................................................................................... 6

3.1 Designing models on CAD software .................................................................................... 6

3.2 Exporting models as .STL or .OBJ......................................................................................... 6

3.3 PreForm ............................................................................................................................... 6

3.3.1 Navigation .............................................................................................................. 7

3.3.2 Select resin and layer thickness ............................................................................. 7

3.3.3 Size.......................................................................................................................... 7

3.3.4 Orientation ............................................................................................................. 7

3.3.5 Supports ................................................................................................................. 8

3.3.6 Layout ..................................................................................................................... 9

4 Set up ...................................................................................................................... 10

4.1 Setting up the Form 1+ ...................................................................................................... 10

4.2 Set up the form finish kit ................................................................................................... 10

5 Print ........................................................................................................................ 11

5.1 Preparing the resin tank .................................................................................................... 11

5.1.1 Checking the resin tank ........................................................................................ 11

5.1.2 Filling the resin tank ............................................................................................. 11

5.2 Sending a part to the printer ............................................................................................. 11

5.3 During the print ................................................................................................................. 11

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6 Finish ...................................................................................................................... 12

6.1 Post print steps .................................................................................................................. 12

6.1.1 Remove the build platform .................................................................................. 12

6.1.2 Use the scraper to remove the print .................................................................... 12

6.1.3 Clean the part in IPA ............................................................................................. 12

6.1.4 Clean the build platform ...................................................................................... 12

6.2 Finishing the part ............................................................................................................... 12

6.2.1 Simple parts .......................................................................................................... 12

6.2.2 Delicate parts ....................................................................................................... 12

6.2.3 Cleaning internal channels and cavities ............................................................... 12

6.2.4 Fixing holes ........................................................................................................... 13

6.2.5 Getting a transparent finish for transparent resin ............................................... 13

7 Maintenance ........................................................................................................... 14

7.1 Form 1+ care ...................................................................................................................... 14

7.1.1 Cleaning the cover ................................................................................................ 14

7.1.2 Resin tank ............................................................................................................. 14

7.1.3 Mirror ................................................................................................................... 14

7.1.4 Resin care ............................................................................................................. 14

8 Quick guide ............................................................................................................. 16

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1 How to use this guide

This guide is a summary of information found at formlabs.com/support/guide/. It should be used to

supplement the official guide, or after an induction to the printer.

For troubleshooting see formlabs.com/support/troubleshooting/.

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2 Basic safety

For a more detailed overview of safety when using the Form 1+ printer please look at the Formlabs

website (formlabs.com/support/guide/safety-first/).

Supervision is recommended while in experienced.

2.1 Laser

The Form 1+ is a Class 1 Laser product and requires caution to be used safely.

The laser beam is harmful to the eyes, so avoid direct contact. The laser is

automatically shut off when the orange cover is opened.

Never remove the front or back panel of the printer. This voids the warranty and can potentially be

dangerous.

2.2 Resin

Treat the resin like any household chemical.

Always wear gloves when handling the liquid resin as it can cause mild skin irritation.

Never ingest the liquid or solid resin. The resin is not approved for use with food, drink or medical

application on the human body.

2.3 Isopropyl Alcohol (IPA)

Follow the individual safety instructions provided for the IPA being used.

Generally, IPA can be flammable and explosive. It should therefore be stored away from

heat, fire or sparks in a closed or covered container.

When working with IPA always wear gloves and make sure the workspace has good ventilation.

2.4 Tools

Some of the tools used (tweezers, scraper, and flush cutter) are sharp and should be used with care

especially against slippery surfaces.

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3 Design rules and PreForm

PreForm can be downloaded (free) for either Mac or Windows at formlabs.com/products/preform/.

3.1 Designing models on CAD software

It is important to consider printability when either: designing a model for printing, or adapting a prior

model for 3D printing. Occasionally designs that were not originally intended for 3D printing contain

unprintable object i.e. windows.

These need to be modified to be printed taking into account the minimum feature size is 300 microns

(0.3mm). Close to this value has a higher probability of failing.

A model must be a water tight mesh to be printed, which can be confirmed on most CAD packages.

Consider the required size required from the print. It may be required to split the print into multiple

prints which can be joined post print.

Fully enclosed cavities are advised to have a drain hole (≥3mm) to allow any trapped resin to escape.

3.2 Exporting models as .STL or .OBJ

PreForm can import either .STL or .OBJ files.

If conversion is required from a 3D CAD format, Meshlab can convert most file formats to .STL or .OBJ.

Meshlab can be downloaded (free) for Mac or Windows from meshlab.sourceforge.net.

The more vertices a model has, the larger the file and the longer PreForm will take to import the

software.

3.3 PreForm

3.3 briefly summarizes the functions on PreForm. For a more in depth overview please view support,

available at formlabs.com/support/guide/.

It is possible to move through the tool bar menu by using the “S”, “O”, “C” and “L” keys for size,

orientation, supports and layout respectively.

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3.3.1 Navigation

Hovering over the “View” icon will open the view controls. It is also possible to navigate by right clicking

and dragging. To zoom use the mouse wheel.

3.3.2 Select resin and layer thickness

Opening PreForm, you will be able to select layer thickness and material.

The smaller the layer thickness the smoother parts will appear. However the longer prints will take.

To select the material and version, use the drop down menus. The version can be identified on the

bottle. If there is a formulation underneath the colour, then the resin is 02. Otherwise the resin will be

version 01. This can be changed on the bottom bar, along with a rough estimation of printing time.

For more information on resins go to formlabs.com/support/guide/prepare/choosing-right-material/.

3.3.3 Size

The scale of the model can be modified. If features are close to 300 microns, it is advised to increase the

scale to reduce the probability of a failed print.

Size can be altered either by adjusting each axis size with the X, Y and Z boxes or by scaling the whole

model by changing the value in the “Scale” box.

It is also possible to modify the units from millimeters to inches.

3.3.4 Orientation

It is possible to change the angle of print by dragging the object with the mouse, or supplying angle sizes

into the X, Y and Z boxes.

Use the “Select Base” option to select the face which points towards the build platform.

Flat surfaces print much more successfully at an angle of 10o-20o due to the “peel” process.

Preform can automatically orient an object. This is done by selecting the object and pressing “Orient

Selected”.

When orientating, aim to reduce overhangs as much as possible as these will be lost in the resin if they

are isolated in their layer.

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3.3.5 Supports

Supports allow overhangs and shallow angles to be printed. They also reduce the risk of air pockets

forming which cause voids in the print.

PreForm automatically generates supports for either all parts on the build platforms or a selected part.

These can be switched between by selecting a specific part or by unselecting all parts.

PreForm shades areas which are unsupported red. The darker the area the less likely of a successful

print.

Checking the “Internal Supports” box allows PreForm to generate supports within the object.

Density of support struts can be adjusted with the slider. This changes the flat spacing value (distance

between struts horizontally). This should be adjusted in accordance to the resin used.

“Point Size” can also be adjusted with the slider. This adjusts the contact point size of the struts. The

smaller the point, the easier it is to remove the part. However it also increases the chance of the support

teeth not supporting the object.

You can manually add and remove supports from the part by using the “Edit Selected” feature. This is

useful for supporting regions that PreForm has missed, or clearing a region where quality is important.

Supports can be added by selecting a point on the surface of the model. Remove a support by clicking on

a point. Internal supports can be added by holding shift and scrolling to move through the part. Then

supports can be added. Once supports have been added, clicking on “Apply Changes” and PreForm will

modify the part.

Advanced settings can generally be left unchanged from default values for most prints.

“Slope Multiplier” adjusts the density of supports for sloped and angled surfaced.

“Base Thickness” can be altered. A thicker base adds support structure stability. However, can be more

difficult to remove from the build platform post print.

“Height Above Base” effects the smallest distance between the base and the bottom of the model. If the

distance is too small, areas of the print may deform or fail due to normal shrinkage.

It is good practice when printing larger parts at an angle to have the tall supports facing the hinge side

(labeled “HINGE SIDE” in the layout view).

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3.3.6 Layout

To increase the life time of your resin tank and maintain high quality prints, it’s important to vary the

location of the print on the build platform.

Make sure the part is within the boundaries.

It is possible to duplicate the object. It is possible to print as many parts as fit in the boundries.

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4 Set up

It is good practice when using the printer to wear gloves at all times

4.1 Setting up the Form 1+

Make sure the printer is on a flat surface where it will not be

subjected to extreme temperatures or direct sunlight.

Attach the power cable to the printer and connect to a wall

outlet.

Press the Form 1+ button to turn on the printer.

Attach the USB cable to the printer and connect the other

end to the computer.

Once the printer is successfully recognized, the “Form” button in the

PreForm software will glow orange.

Slide the resin tank into the tank carrier until it clicks into place. Take care never to touch the

bottom or top of the tank. Slide the build platform into position and secure it by pushing the

hinge down.

It is essential to remove the build platform before removing the resin tank so as not to drop material

inside the printer body.

4.2 Set up the form finish kit

The finish kit consists of: the finishing tray, a wash bucket, rinse pad,

squeeze bottle, absorbing foam pads, scraper, flush cutters and

tweezers. It should be set up similar to the diagram and

located close to the printer.

Set up the rinse basket and place it in the wash bucket. Then

fill the wash bucket with IPA (Isopropyl alcohol. Recommended at

90+% concentration). Also fill the squeeze bottle with IPA.

Place the foam pads in one block of the finishing tray and place the scraper and

tweezers on the foam pad.

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5 Print

This section assumes the printer has been cleaned properly after prior use.

5.1 Preparing the resin tank

5.1.1 Checking the resin tank

A tank must be optically clear for a successful print. Inspect the tank before confirming a print.

For a tank that has been previously filled with resin, use the scraper to check the tank by pulling it back

along the tank at a shallow angle. Take care not to let the resin overflow out of the tank. If any resin has

cured to the bottom of the tank, gently use the scraper to remove it. Use a comb to sift for fine particles

in the tank.

5.1.2 Filling the resin tank

Shake the resin bottle (especially for coloured resin).

Pour the resin into the tank, taking care not to exceed the maximum line.

5.2 Sending a part to the printer

Once ready to print on the PreForm software (see section 3.3) click send to printer. A pre-print check list

will pop up confirming that the resin tank is clean and filled with resin. Once these have been checked,

click send to printer. Confirm the print on the printer by pressing the button.

Do not disconnect until the file transfer is complete.

5.3 During the print

The resin tank holds 200ml of material. PreForm will estimate how much resin will be required for the

print. To add resin, pause the print by pressing the button on the printer and then fill the resin tank

slowly, not exceeding the maximum line. Close the lid to restart the print.

To cancel a print hold the button for 3 seconds.

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6 Finish

6.1 Post print steps

6.1.1 Remove the build platform

Remove the build platform by opening the hinge and pulling it out. (Make sure to do this before

removing the resin tank). Place the build platform on the stand of the finishing tray. Close the cover of

the printer immediately.

6.1.2 Use the scraper to remove the print

Use the corner of the scraper under the quick release tabs of the base. Quick release tabs are the slightly

raised areas of the base.

6.1.3 Clean the part in IPA

Place the part in the wash basket on the rinse basket. Use the rinse basket to soak the entire part for 2

minutes, then allow the part to soak in fresh IPA for 10 minutes.

6.1.4 Clean the build platform

Using the squeeze bottle to administer IPA, use a paper towel to clean the build platform

6.2 Finishing the part

6.2.1 Simple parts

For simple parts, peel the supports off the finished part. Sand the print to remove marks from the

supports. Remove the white finish with mineral oil.

6.2.2 Delicate parts

For more delicate parts, if practical, use the flush cutters to break the base into sections. Then use the

flush cutters to remove the supports to the point that the part can be safely peeled off the last supports.

6.2.3 Cleaning internal channels and cavities

Use a syringe and compressed air to clear trapped resin from inside a part.

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6.2.4 Fixing holes

If the print has small holes in it, it is possible to use: a toothpick, the Formlab resin and sand paper to fix

them. Use the toothpick to accurately fill any holes and then let the resin cure in sunlight or use a

405nm laser pointer. Once cured, use the sand paper to make the surface smooth.

6.2.5 Getting a transparent finish for transparent resin

Important for showcasing internal design.

Wet sand the part, then use acrylic cleaner on a cork board. Then polish the part with a microfiber cloth

and finish with acrylic spray (optional).

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7 Maintenance

7.1 Form 1+ care

7.1.1 Cleaning the cover

The cover is made from Acrylic, which cannot be cleaned with IPA. Use specialized acrylic cleaner and

the supplied microfiber cloth to clean it.

7.1.2 Resin tank

Inspect and clean the resin tank after every print. Follow the steps in section 7.1. Make sure not to touch

the base or top of the tank. If the base requires cleaning, use a specialized acrylic cleaner and a

microfiber cloth. Do not use IPA or paper towels to clean the base or top of the tank.

Unopened resin tanks can be kept in their box. Opened resin tanks must have their black lid on to

prevent exposure to sunlight. They can be stacked and it is recommended to store them out of direct

sunlight. The orange acrylic will prevent light from curing the resin within the tank.

It is difficult to clean the inside of a resin tank, and therefore it is advised to use one resin tank for a

specific resin.

To maintain quality prints, replace the resin tank if it becomes cloudy.

7.1.3 Mirror

It is extremely important that the printer is kept clean at all times. It is advised to call Formlab’s

customer support before cleaning it.

After first removing the build platform then resin tank, it is possible to check the mirror using a light for

dust or resin. Clean the mirror with compressed air. Direct the air by bending the straw to prevent liquid

effecting the mirror. If the mirror requires additional cleaning, see:

formlabs.com/support/troubleshooting/cleaning-mirror/.

7.1.4 Resin care

Resin should be stored in a cool dry place out of direct sunlight in a sealed container away from any

ignition sources.

Resin has a finite life of 12 months. After this time it should be replaced. Never return resin from the

resin tank to the bottle. It should be agitated regularly to prevent the pigment in coloured resins

settling.

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Clean up liquid resin spills immediately to prevent it curing on the surface.

Observe local regulations when disposing of liquid resin (or cure it before disposal). Cured resin can be

disposed as normal.

For more information on the different resins available see formlabs.com/support/guide/print/.

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8 Quick guide