I appreciate the advice, especially the recommendation to use side cutters to get prints off the Form 3 build platform. As discussed in another thread, Form 3 print adhesion is much stronger than Form 2. FL support also recommended putting the platform with models still attached in the freezer as another technique that works, too. I have not tried the freezer technique because the time required would disrupt an already tight production schedule crippling my ability to meet customer orders. But for others, it may be a good method. Your recommended side cutter technique is working.
For the last 3 of 9 nameplate prints, I did increase support density by manually adding supports, over 100 more supports to each nameplate. Those 3 nameplates were essentially saturated with supports. I regret to report that the addition of supports did not eliminate the warp. This tends to indicate that support density is not the cause of the warp.
Several months ago, I first contacted FL support about terrible Form 3 print quality compared to Form 2, stating that unlike the Form 2, my Form 3 was not capable of printing a sellable model (see photo below). Models were warped, there was significant layer shifting present and openings were misshapen, etc. Models printed on my Form 2s never exhibited these artifacts.
At that time, FL support was in complete denial there was anything wrong with the Form 3. Reps repeatedly stated or implied that Form 3 print problems were caused by user error or user unfamiliarity with 3D printing. FL rep responses to my claims explicitly stated that Form 3 print failures could be easily corrected by the user by changing model orientation and/or increasing support density through an iterative process until a successful print was achieved.
With over 1500 successful prints on the Form 2, and having been specifically told that the concept of low-force SLA would mean fewer supports would be needed and even smaller attachment points would be needed compared to the Form 2, the advice seemed to be completely inconsistent with the concept and benefits of low-force SLA. If low-force SLA required fewer supports than the Form 2, why would the Form 3 need more supports than the Form 2 to achieve a successful print? But anxious to get something, anything, sellable out of the Form 3, I made numerous, costly attempts to follow FL advice precisely. Despite these efforts, there was no improvement.
Only after some months did an FL rep admit that FL had come to recognize that the problems my Form 3 was having were real, common, had become known to FL engineers, and that the problems could not be solved by the user. The problems could and would be resolved through future firmware and PreFrom updates.
Firmware and PreForm updates as the likely solution were again recommended by FL reps as late as March. At that time, a FL support rep contacted me concerned about my Form 3’s abysmal success rate and asked what was happening and if FL might be able to help (kudos to FL reps for monitoring customer success rates and reaching out). FL considered the possibility that the problems were specific to my machine and that a “hot swap” may be needed. But after evaluating photos of failed prints, the FL support rep stated that the serious print quality problems I was experiencing (warped prints and serious layer shifting) remained common and known, and a replacement printer was not likely to print any better. He stated these issues were being worked on by FL engineers and future firmware and PreFrom updates would come.
As promised, Preform update and firmware update to version 1.6.8 did in fact resolve many of the print quality problems my Form 3 was experiencing. But, the warped nameplates indicate not all Form 3 problems have yet been fixed.
The model on the right is how every model was coming out of my Form 3 prior to the update to firmware 1.6.8. Obviously, not sellable in that condition.
Whatever the cause of warped models, the user is not likely to be able to fix them. More firmware improvement is needed. That Form 3 printing at 50 microns and 25 microns is still in beta tends to indicate that FL engineers are not yet satisfied with Form 3 performance at those resolutions. Only FL can make the necessary improvements needed to achieve satisfactory quality and resolution certification.
I wish to emphasize yet again that the Form 2 does not have any of these issues and prints models I designed, including nameplates, perfectly at all available resolutions with no need for an iterative process. The print quality problems my Form 3 is experiencing are Form 3 specific, very real, and are serious. I anxiously await the firmware and/or PreForm update that will fix warping.