There are environmental factors that also play in to the longevity of a product like the Formlabs printer. The optics are susceptible to contamination and degradation, and while the spontaneous failure of a laser (vs. slowly losing power) is rare, it’s not unheard of. So just sitting around for 3 years being used intermittently doesn’t necessarily support an argument that it should not have failed. It sucks, I agree. But it’s not really something FL needs to do something about…
I deal with customer support in my “day job”. Unfortunately, out of warranty means exactly that. There’s no mitigation for circumstance. Even if you’d never taken it out of the box, it’d still be out of warranty. Manufacturers have to do this to protect themselves from unnecessary warranty claims. You might not be the kind of person who’d try and “game the system” but there are plenty of people out there who would, given the chance. No exceptions to warranty. If I even considered it, my lawyers would flay me alive.
If it’s any consolation, my Form2 failed about a year out of warranty. I had certainly run more than 7L of resin through it by then. But not a huge amount more, I’m a hobbyist, I use the printer on average maybe about once every couple of weeks.
I took the $500 and traded up to a Form3. I think I also paid for the extended warranty this time.