Formlabs Reduces Lead Time by 20% in Customized 3D-Printed Parts Production

A Built(Print)-to-Order Facility Running into Issues with Paper

Formlabs is a leading company in 3D printing technology, renowned for its high-quality desktop SLA and SLS 3D printers. They offer professional-grade printers, resins, and software solutions for industries like engineering, healthcare, and education, making precision printing accessible and advanced additive manufacturing technology widely available.

Formlabs has a facility in Ohio specializing in sample parts production, providing customers a seamless ordering experience and a 1-5 day turnaround time depending on the post-processing steps required for their parts.

The facility faced operational hurdles due to manual paper processes and the use of Google Sheets for tracking its operations. This approach resulted in data inconsistencies, challenges in tracking parts, and difficulties managing custom requirements effectively. With no MES system in place, the need for a comprehensive solution to streamline operations and enhance efficiency became paramount.

Streamlining Built-to-Order Operations with a Cloud-Based MES

In response to these operational challenges, the Operations Systems team at Formlabs turned to Tulip to create an app-based Manufacturing Execution System (MES) to manage their built-to-order part printing and post-processing processes at the Ohio facility. The team built a series of apps in a few months as the local team simultaneously built out the new facility, launching production with a fully-built MES. Since then, they have adjusted and enhanced their systems on an ongoing basis.

The MES they built allows for a streamlined built-for-order process for customers and the frontline of operations. After a customer orders a custom part(s) with Formlabs ordering software, the order is sent to Tulip for end-to-end tracking and operator guidance—from production initiation to finishing options. After the print job is complete, Tulip prompts operators to move the parts to the post-processing steps defined in the ordering process. Operators are guided through key procedures such as washing, blasting, curing, quality checks, and finishing.

1. Order Confirmation: Customers place orders in Formlabs’ PreForm software via an order portal. These orders flow into Tulip through external scripts and utilizing the Tulip API.

2. Printing: Tulip assigns the print to an open printer with API-based logic. Once an order starts printing on a 3D printer, the progress of each part is tracked within Tulip through the various stages until the part is ready for shipping.

3. Wash Station: Parts are removed from the build platform and given a QR code label. They undergo washing in isopropyl alcohol as instructed by Tulip. The system provides operators with specific criteria for washing based on resin type and part specifications.

4. Data Capture: Barcodes are scanned to capture data on each part. Information is recorded on wash cycle times and idle time between stations for process optimization.

5. Inspection Stations: There are two inspection stations after washing. Operators confirm the correct parts and quantities using visual guides and STL files. Defects are identified and logged, and images are captured for quality tracking.

6. Curing: Post-inspection, instructions are provided to operators based on the resin type for the necessary curing time and temperature. Operators follow these instructions for proper curing.

7. Finishing Options: Based on customer preferences, parts may move to the finishing station for post-processing, such as support removal or sanding. Tulip guides operators on the required finishing processes based on customer input and specific part requirements.

8. Final QC and Consolidation: After passing the final QC, parts from multiple builds within an order are consolidated into a designated bin. Once all parts are gathered in the bin as per the order, Tulip marks it as ready for packing. Operators at the QC stage have the option to quarantine certain parts if uncertainty exists regarding acceptance criteria. This serves as an escalation step where an ADM manager may be involved or escalated to customer approval if necessary.

9. 3D Scan: After consolidation, the operator uses a photo-booth device, Ortery, to scan the final parts to create 360-degree images that are made available to the customer as a GIF.

10. Shipping: At the shipping station, the shipper receives a notification indicating the packed bin is ready for shipping. The shipper conducts a final quality check, confirms quantities, and provides packaging details such as dimensions and weight. An integration with Shippo allows for the creation of shipping labels and packing slips, with a confirmation photo taken before packing. After the package is sent, the system updates all platforms, including Tulip and the order management system, to reflect that the parts have been shipped.

As operators complete each step of the procedures, Tulip is updated and supervisors can see where a specific part is in production. With this real-time data, the Formlab team has also built dashboards to monitor performance.

The Operations Systems team developing the apps used by the facility in Ohio is partially based in Massachusetts. Virtually and periodically on-site, the team engages with the local Ohio team in regular meetings to discuss enhancements, gather feedback, and make adjustments based on user input. Changes in colors, fonts, button placement, and functionalities are implemented to optimize user experience and streamline operations, ensuring that updating apps is a collaborative and iterative process. Additionally, the team can analyze production data to identify opportunities for continuous iteration and refinement to enhance operational efficiency.

The composable nature of Tulip’s platform makes it easy for Formlabs to adapt their operations. With reusable, modular apps and components, they can add apps for new production lines or adjust an existing set of apps for a line undergoing changes in just a few weeks.

After the release of their new printer, Formlabs installed several of these new printers at the Ohio facility for customers to expand the variety of options for customers ordering parts. Customers can also order test parts and resins before investing in the new printer for their own sites. With the existing apps, the Operations Systems team was able to get the new apps up and running quickly to reflect the changes to production.

Driving Operational Improvements

The adoption of Tulip yielded substantial improvements for the facility:

• ~20% reduction in cycle time due to automated workflows, real-time data capture, and quicker issue resolution.

• 100% reduction in defect logging time and lower defect rates with Improved quality control including inspections, consistent quality checks, and real-time feedback.

• 20-25% shorter lead times with improved scheduling, optimized production planning, and faster order processing.

• ~ 20-30% increase in operator productivity with automated data entry, real-time work instructions, and efficient task management. Operators can now process more parts in the same amount of time.

• Improved compliance and traceability with automated record-keeping, consistent documentation, and easy access to historical data.

Note: Tulip and Formlabs have a shared history, including a shared co-founder who is Tulip's CEO and the Chairman of Formlabs' Board of Directors.