Form 4BL: Maximum Throughput at Blazing Speed

Introducing the Form 4BL, the fastest large-format dental SLA printer designed for printing high-quality dental models and biocompatible parts. Whether you're looking to boost model production or quickly create biocompatible appliances, the Form 4BL delivers exceptional speed, accuracy, reliability, and ease of use—just like its predecessor, the Form 4B—but with a build volume that's 4.6 times larger.

This advanced technology allows the Form 4BL to print up to 2-4 times faster than the Form 3BL, making it possible to produce over 120 orthodontic models per hour. With a 2.7x larger build surface than the Form 4B, you can run multiple batches in a single day with minimal user intervention, maximizing your lab’s efficiency.

For labs with high throughput demands, the Form 4BL offers the speed, precision, and reliability needed to produce accurate, high-quality dental appliances efficiently and cost-effectively.

The Form 4BL leverages the same proven technology as the Form 4B, delivering fast speeds without compromising on accuracy. It features quicker heating and 5-10x faster resin dispensing, so prints start sooner. Once printing begins, you can achieve print speeds ranging from 10-80 mm/h, depending on the material used.

With the Form 4BL, you can print 32+ models in Fast Model Resin at 160 μm in just 15 minutes, achieving a throughput of over 100 models per hour. Print time remains consistent whether you’re printing one part or many, allowing you to plan your workflow more efficiently without worrying about case volume affecting your schedule.

The ~1.8x increase in throughput with the Form 4BL comes with three times fewer user interactions compared to the Form 4B. Printing with the smaller build platform on the Form 4B requires users to remove and reinsert the build platform three times to match the output of the Form 4BL. This means you can produce more models in less time while freeing up staff for higher-value tasks—all while maintaining the same level of precision and accuracy.

Aurora DTC was among the first to adopt the Form 4BL, and the results have been impressive. Rich Heilweil, the Rapid Prototyping Team Lead, says, “It’s unique, something different for us. It’s very productive to be able to nest so many models at once and print in one run. It’s a big advantage for us.”

At Aurora, they dedicate each printer to specific resins and applications. The Form 4BL is used with Precision Model Resin to print highly accurate implant models and dies at a 50 μm layer height.

Milos Markovic, Director of Cad-Cam and Implantology at Aurora DTC, emphasizes that accuracy and speed are key when choosing a 3D printer. He was impressed by the finish and quality of the Precision Model Resin, and the Form 4BL not only offers blazing speeds but also meets their high-throughput needs.

Rather than running multiple print runs on the Form 4B, each requiring user interaction for removal and post-processing, the Form 4BL allows Heilweil to batch print, reducing the number of builds required. Fewer print runs mean fewer interruptions, giving him more time for other essential tasks while maintaining or increasing daily model output.

While models are the highest volume application at Aurora, Markovic sees potential for future biocompatible printing. As intraoral scanning becomes more common, the demand for digital dentures is growing. Markovic envisions a future where large-format 3D printing of biocompatible resins could revolutionize production.

Dental professionals need reliable, high-quality prints to meet deadlines. Knowing that a print will succeed keeps your workflow smooth and efficient. The Form 4BL solves common pain points, offering faster, more reliable, and easier operation and maintenance than previous large-format SLA 3D printers.

Inside the printer, six intelligent control systems ensure precise measurement and maintenance of temperature, resin levels, print forces, and print status. Plus, with remote monitoring, you can track and manage your prints from anywhere using an integrated camera, preventative maintenance reminders, and our free Dashboard software.

Reliability starts at the factory with a 60-point calibration and quality inspection, ensuring the Form 4BL is ready to print right out of the box. We know downtime is costly, so we've redesigned our consumables for long-term use. Resin Tanks for the Form 4BL last an estimated 75,000+ layers, and the Light Processing Unit 4L (LPU 4L) lasts 600k - 1.9M layers. When replacement is needed, the LPU 4L is easy to install, minimizing downtime and keeping your operations running smoothly.

At Kreimer Dentallabor, Stephan Kreimer, MDT, found that adding the Form 4BL to his fleet increased productivity and efficiency. As a full-service lab, over 80% of their customers are digital, meaning they produce a high volume of dental models—around 30-50 per day.

Managing this volume of models plus manufacturing appliances with a team of 12 would be impossible without reliable, high-throughput 3D printing. High labor costs and limited access to skilled technicians make efficiency and cost-savings top priorities.

While the team loved the speed and accuracy of the Form 4B, the quick print batches required frequent movement between tasks and the printer. With the addition of the Form 4BL, these interactions were reduced by more than 50%. Now, Kreimer Dentallabor can batch models together, saving time and reducing distractions.

“You spend much less labor time on cleaning, washing, and curing because you can process three times more models at once. The time needed for post-processing 30 models is almost the same as for 10 models,” says Kreimer.

Kreimer’s team found that learning to print on the Form 4BL was as intuitive as earlier Form Series printers, minimizing the time it takes to onboard new team members, whether they're new to the printer or the lab. As Kreimer says, “everyone can do it in 15 minutes.”

Learn more about how Form 4B and Form 4BL drive efficiency at Kreimer Dentallabor in our case study.

Reliably producing precise, accurate parts with a perfect fit is essential for dental professionals—whether it's restorative models with removable dies and implant analogs, or final restorations that look life-like and adapt perfectly. Parts printed on the Form 4BL have ±0.15% XY dimensional tolerances across the build platform, ensuring they match your design parameters every time.

The Form 4BL features the same technological advancements as the Form 4B. Highly collimated light and 46 µm pixel size with pre-tuned anti-aliasing for subpixel resolution and lower peel forces allow you to achieve the sharpest details and smooth surfaces.

Formlabs' dental material library includes 15+ materials, including seven biocompatible resins. These biocompatible resins can be printed on Formlabs biocompatible printers, including the Form 4BL. Formlabs' biocompatible resins are developed and manufactured within our ISO 13485 and EU MDR certified Quality Management System. Scale occlusal splint production with Dental LT Comfort Resin or Dental LT Clear Resin, or maximize surgical guide production to meet your customers' needs.

All Formlabs resins are validated on the printer, with optimization engineers testing hundreds of printed parts to dial in validated print settings for reliable printing right out of the box. Print highly precise and accurate restorative models with Precision Model Resin, or leverage the speed of Fast Model Resin to produce 120 orthodontic models per hour.

Users seeking more flexibility can take advantage of Formlabs' open ecosystem on the Form 4BL. This includes the Print Settings Editor, which allows fine-tuning of print parameters to meet specific needs, and the Open Material Mode (OMM), enabling broader material compatibility.

OMM empowers expert users to leverage the speed, accuracy, and heating capabilities of the Form 4BL to print with any third-party 405 nm photopolymer resin. To learn if OMM is a good match for your business goals, talk to a dental sales representative.