We are currently seeing. a major shift toward smarter, faster, and more Integrated additive production. Three areas are defining the change, including, next-generation materials, automation and system integration and process intelligence. Together, these changes are shifting tooling from a purely
preparatory role into an enabling layer for faster product cycles, localized manufacturing, and more sustainable, on-demand production models,” says Michael Agam, General Manager APAC, Formlabs, in conversation with Neha Basudkar Ghate.
In what ways is automation advancing additive manufacturing towards fully digital and 24/7 production environments in industrial tooling?
Automation is transforming 3D printing from a manual, workshop-level technology into a predictable, always-on production capability. Three key elements are converging: integrated hardware ecosystems (printers, automated wash/cure stations, and material handling), software orchestration (print farm management, remote monitoring, job queuing, and analytics), and factory-level digitization (MES/ERP integration, digital twins, and predictive maintenance). Together, these enable ‘lights-out’ operation—continuous, scheduled builds, automated post-processing, and remote error handling—significantly improving equipment utilization and reducing lead times for tooling and modular fixtures.
At Formlabs, our Fleet Control and High Volume Resin System enable coordinated job scheduling, printer grouping, and resin replenishment, minimizing downtime and manual supervision. Many customers now operate 24/7 production environments using Formlabs printers for end-use applications. For example, DHR Engineering in the U.S. has automated its Form 4, Form 4L, and Fuse 1+ 30W systems with robotic handling to continuously restart jobs and eliminate idle time, effectively doubling output within the same footprint.
What current trends in high-performance resin materials should tooling designers consider to improve the durability and functionality of additively manufactured tools?
Tooling designers should evaluate resins across three axes: mechanical performance (impact strength, elongation, heat deflection), process compatibility (post-cure behavior, support strategy), and end-use properties (chemical resistance, surface hardness). Materials like Tough 2000, Rigid 10K, and High Temp Resin are ideal for functional jigs, fixtures, and mould masters exposed to mechanical stress or elevated temperatures. Additionally, Clear Resin has become an important tool for engineers who need transparent moulds or flow-visualization tools, allowing them to observe part behavior and fluid dynamics during testing or casting. These advancements bring additive materials closer to traditional engineering performance while preserving the digital flexibility of 3D printing.
How has the evolution from traditional stereolithography (SLA) to advanced Low Force Stereolithography (LFS) transformed the precision, surface quality, and reliability of 3D-printed tooling components?
The transition from conventional SLA to Low Force Stereolithography (LFS) has been a breakthrough for precision and repeatability. Low Force Stereolithography (LFS) fundamentally reduces the physical stresses that form on parts during printing. By lowering peel and separation forces, LFS enables finer features, smoother surfaces, and lighter-touch supports that are easier to remove without damaging delicate geometry—all of which increase first-pass yield for tooling components. Practically, this means tighter tolerances on snap-fits, better surface fidelity for mould masters, and fewer scrapped parts from support-related failures. LFS also scales to larger formats with better reliability because the print process places less mechanical strain on both the part and the optics, which improves repeatability across long print runs.
Our Form 4 series, which uses advanced LFS and next-generation light engine technology, achieves sub-100 micron resolution and exceptional surface finish—critical for tooling components where dimensional accuracy defines performance. For manufacturers, this translates to less post-processing, reduced scrap rates, and the ability to print production-ready tools directly from CAD.
What impact do large-format, high-speed resin 3D printers have on enhancing production capacity and scalability for large tooling, die, and mould parts?
Large-format and high-speed resin 3D printers dramatically improve scalability by enabling the production of bigger, more complex tooling components in fewer print cycles, which previously required assembly or expensive machining. With the Form 4 and Form 4L, users can achieve up to five times faster print speeds than legacy SLA systems while maintaining precision and surface quality.
This increase in throughput allows toolmakers to iterate and deliver faster, or even produce short-run end-use parts directly. The larger build volume of the Form 4L eliminates the need to section and assemble large moulds, improving structural integrity and cutting assembly time and cost. When combined with automated post-processing and farm management, large-format systems provide a route to scaled, cost-effective production of large moulds, patterns, and master tools.
How are specialized resin materials, including colour-customisable and casting pattern resins, enabling new design possibilities for custom tooling and improved casting accuracy?
Specialized resins are unlocking functional workflows that previously required multiple processes. Colour-customisable resins speed part identification, fit-checking, and communication across design and production teams, and help create customer-ready prototypes without additional finishing. Formlabs’ Clear Cast Resin and Castable Wax Resin have been widely adopted for creating high-accuracy burnout patterns in industrial casting. These resins ensure smooth surface finish and clean burnout, improving dimensional precision in the final cast.
Meanwhile, transparent materials like Clear Resin are used for visual tooling prototypes or moulds where internal flow and part alignment can be observed. These specialized resins bridge the gap between design validation and final tooling, helping teams optimise before committing to metal production.
What are the key post-processing challenges for resin 3D-printed tooling components, and how can they be addressed to meet critical surface finish and dimensional tolerance requirements?
The main post-processing challenges include achieving consistent surface finishing, removing supports, and maintaining dimensional accuracy through curing. The solution lies in standardising the post-print process. Formlabs’ Form Wash and Form Cure systems automate cleaning and curing steps, ensuring repeatable part quality with minimal manual handling.
For production-scale operations, our Fleet Control software helps coordinate print and post-process workflows across multiple systems, ensuring that parts move through cleaning and curing in sync. When tighter tolerances are required, light finishing or polishing can complement the additive process to meet industrial-grade standards.
Looking ahead, what developments in 3D printing technologies and materials are expected to significantly transform tooling, die, and mould manufacturing within the next five years?
The next five years will bring a major shift toward smarter, faster, and more integrated additive production. Three areas will define this change:
- Next-generation materials: Engineering-grade, fibre-reinforced, and high-temperature resins that match thermoplastics in strength and durability.
- Automation and system integration: End-to-end workflows where printers, post-processing units, and robots work in tandem to eliminate downtime and manual intervention.
- Process intelligence: AI-driven print monitoring and adaptive correction that improve first-time-right yields and traceability.
Together, these changes will shift tooling from a purely preparatory role into an enabling layer for faster product cycles, localized manufacturing, and more sustainable, on-demand production models.
At Formlabs, we’re investing in these directions—from the Form 4 ecosystem for high-speed resin printing to the Fuse 1+ 30W platform for durable, industrial SLS parts. Our vision is to make additive manufacturing a cornerstone of modern tooling, enabling faster iteration, localized production, and higher overall manufacturing efficiency.
This interview was published in TAGMA Times
COMMENTS