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FormLabs Facility Tour: Exploring 3D Printing Innovation
0:00:01 Company Overview: FormLabs considers itself one-third software, one-third hardware, and one-third materials. The company's founders acknowledge the challenge they undertook, combining naivete and intelligence to succeed.
0:00:40 Introduction to FormLabs: Max Lowsky, co-founder and CEO, showcases the company's hardware products, including the Form 3, 3B, 3L printers, post-processing systems, and the Fuse 1 (selective laser sintering printer).
0:02:29 History: The Form 1, launched via Kickstarter in 2012 and shipped in 2013, was among the first to bring high-resolution stereolithography (SLA) 3D printing to the desktop at a professional level.
0:03:28 Materials Diversity: FormLabs emphasizes its wide range of materials, including biocompatible, high-stiffness, glass-filled, fire-resistant, jewelry (lost wax casting), and polyurethane options.
0:04:55 SLS Technology Deep Dive (with Ian Ferguson): Ian Ferguson, a lead hardware engineer, explains the Selective Laser Sintering (SLS) process used in the Fuse 1. The process involves manipulating powder, heat, and optics (laser) to fuse powdered thermoplastic into solid objects.
0:07:43 SLS System Components: The Fuse 1 has three main systems: powder manipulation (including a unique, mechanically self-regulating dosing mechanism), heat management (using radiation, conduction, and convection), and an optical system for laser sintering.
0:09:46 Operating Temperatures: Nylon prints at 180°C, while PA11 can reach 190°C. The high temperatures pose challenges for component selection, especially for gaskets and polymer bearings.
0:11:51 In-House Galvanometer System: FormLabs designed its own galvanometer system for laser steering, optimizing for accuracy over speed, and addressing cost concerns with commercially available options. The laser used is a different wavelength than the one of their SLA printers (1064nm).
0:15:16 3D-printed Parts: The ability of SLS to produce complex, interconnected parts in a single build is highlighted. Examples include a chain, robotic components, and soft TPU prosthetics.
0:18:19 SLS Lab: This lab is used to refine the SLS hardware and process and also features an automated media blasting system.
0:20:34 Automated Media Blasting: Media blasting cleans the prints of powder and is a big labor-saving step. Blasting system uses ionized air and "wacky noodles" for a turbulent flow of air.
0:23:12 Internal Print Farm: A dedicated print farm within the facility houses numerous Fuse printers used for internal engineering, R&D, and new materials development.
0:23:50 Critical 3D-Printed Part: A 3D-printed part is used to maintain the cleanliness of the IR temperature sensor, a crucial component for preventing meltdowns.
0:25:07 Machine Shop: The in-house machine shop provides capabilities for quick prototyping and modifications, including vacuum forming, water jet cutting, and furnaces for ceramics.
0:28:41 Measurement Equipment: Equipment like a CMM (Coordinate Measuring Machine) and an optical 3D scanner are used to ensure printer accuracy and fine-tune the printing process, especially for benchmark parts.
0:31:14 Industrial Design Studio: FormLabs conducts its industrial design in-house, leveraging 3D printing extensively for iterative prototyping.
0:33:21 Materials Testing Lab (with Adam): Extensive material testing occurs, including mechanical (tensile, flexural), thermal, and rheological analysis.
0:36:22 Dynamic Mechanical Analysis (DMA): A DMA machine measures material response at varying frequencies and temperatures, providing insights into creep and other properties.
0:38:50 Rheometer: The Rheometer measures the properties of liquid resin, which impacts printing.
0:41:27 Climate-Controlled Environment: The testing lab maintains a controlled temperature and humidity (75°F, 50% relative humidity) for consistent material testing.
0:42:31 Impact Testing: Various impact tests (notched Izod, Gardner impact) assess material toughness and resistance to cracking.
0:45:40 Settings Optimization: A large bank of printers (around 100) continuously runs benchmark parts to fine-tune the print process across different materials and geometries. Hundreds of thousands of parts are tested yearly.
0:48:35 Materials Lab (with Sharon Song): Multiple lab units support advanced chemistry work, including resin formulation, synthesis, and analysis. The labs house equipment for particle size analysis, molecular weight distribution (GPC), and volatile component identification (GCMS).
0:55:36 Chemical Compatibility Testing: Resin compatibility with various plastics is tested to ensure proper material selection for printer components.
0:55:40 Biotech Capabilities (BL1 Lab): A dedicated biosafety level 1 (BSL-1) lab with a HEPA filter enables cytotoxicity testing for biocompatible materials, significantly speeding up development.
0:57:39 Hackathon Projects: Large-scale 3D-printed models (Mecha Godzilla and Mecha King Kong) built during company hackathons showcase the capabilities of the Form 3L printer.
0:58:30 Summary The video concludes that form labs has extensive and comprehensive capabilities in house.