Category: 3D Printing
Inside Formlabs’ R&D Workflow: Combining SLA 3D Printing with the Mayku Multiplier for Faster, Scalable Product Development
Time is one of the most valuable resources for research and development teams. Whether you’re prototyping a new component or preparing for low-volume production, the goal is always the same: to find the most efficient path to a working solution without compromising quality. That’s where hybrid manufacturing comes in.
By combining SLA 3D printing with pressure forming, companies like Formlabs are unlocking faster, more flexible ways to build, iterate, and scale.
What Is Hybrid Manufacturing?
Hybrid manufacturing refers to the integration of multiple fabrication technologies such as combining resin-based SLA 3D printing with desktop pressure forming into a single workflow. While 3D printing is ideal for rapid prototyping and custom part production, pairing it with pressure forming allows teams to move seamlessly into short-run production using durable, functional materials.
This powerful combination reduces turnaround times, lowers production costs, and improves surface finish and part performance making it especially valuable for engineering teams transitioning from prototypes to real-world applications.
Why Formlabs Combines SLA Printing and Pressure Forming
Formlabs, a global leader in professional desktop 3D printing, doesn’t just sell cutting-edge technology, they use it. Inside their Boston-based headquarters, Formlabs’ R&D team relies on hybrid manufacturing to prototype, test, and produce parts entirely in-house.
Their full-stack machine shop includes CNC machining, laser cutting, casting, and SLA 3D printers, all of which empower engineers to maintain complete control over the product development cycle. By integrating the Mayku Multiplier, a compact desktop pressure former, into their workflow, Formlabs has dramatically increased both the speed and scalability of their prototyping process.
The Power of the Mayku Multiplier in Formlabs’ Workflow
A standout example of this approach was the development of a protective IR sensor cover for the new Form 4 printer. The part needed to be both durable and precisely formed to prevent resin leaks that could damage sensitive components.
To solve the challenge, the Formlabs team used their SLA 3D printers to create accurate molds and then leveraged the Mayku Multiplier to pressure-form thermoplastic covers. The result? A functional prototype completed in just days without the need for costly outsourcing or long lead times.
Faster Prototyping With SLA Molds and Pressure Forming
Mayku Multipler heating up material
Multiplier pressure formed IR sensor covers on a Formlabs SLA 3D printed mold.
By pairing SLA-printed molds with pressure-formed parts, the Formlabs team rapidly iterated through designs, testing each version in real-world conditions. What would typically take weeks via third-party vendors was completed in-house in a fraction of the time. This hybrid approach turned a traditionally linear process into an agile, feedback-driven workflow.
“Being able to go from idea to prototype in a day or two changes how we work,” said Mechanical Engineer Jennifer Lu. “It lets us test faster, learn faster, and stay focused on building a better product.”
Real-World Results: Same-Day Prototyping With Mayku and Formlabs
The Mayku Multiplier delivered production-quality parts even on intricate geometries making it a reliable tool for daily use. Its ability to form parts quickly and in high detail helped the Formlabs team speed up testing, reduce iteration time, and boost product development velocity.
Franko Kosic-Matulic, Machine Shop Coordinator at Formlabs.
The finished pressureformed sensor cover after postprocessing
“We can definitely rely on the Multiplier to give us really high detail and also form quickly and produce a lot of parts,” said Machine Shop Coordinator Franko Kosic-Matulic.
What Hybrid Manufacturing Means for Engineers and Product Developers
The collaboration between Formlabs and Mayku is a compelling example of how hybrid manufacturing can elevate modern product development. By combining SLA 3D printing with pressure forming, engineers gain access to a faster, more repeatable, and cost-effective workflow ideal for prototyping, testing, and small-batch production.
Whether you’re a mechanical engineer, industrial designer, or lab manager, this approach shows how the right combination of tools can transform the way you work.
At Dynamism, we’re passionate about helping our customers succeed in additive manufacturing. Whether it’s schools, makerspaces, or businesses, our goal is to provide the tools and resources they need to innovate and grow. We’ve been deeply involved in education, working with schools, universities, and makerspaces to build impactful print labs that foster creativity and hands-on learning. We believe 3D printing is a key part of STEM education, helping students develop problem-solving skills and think like innovators. That’s why we’re excited to sponsor Make48 2025, alongside Ultimaker and MakerBot! This partnership reflects our commitment to supporting creators, problem solvers, and future innovators with the tools they need to bring their ideas to life.
What is Make48?
Make48 is an intense 48-hour invention challenge where teams of makers, engineers, designers, and everyday problem-solvers compete to turn ideas into tangible prototypes. Participants are given a real-world challenge and access to a wide range of tools, mentors, and resources to create working prototypes. The event ends with presentations of each team’s product to a panel of judges, with winners receiving opportunities to take their inventions even further.
Why Dynamism is Sponsoring Make48
At Dynamism, we’re all about helping innovators push the boundaries of what’s possible with 3D printing. That’s why we’re excited to support Make48—it’s a perfect fit with our mission. This competition gives creative minds the chance to tackle real-world challenges using cutting-edge tools. By teaming up with Ultimaker and MakerBot, we’re making sure participants have access to top-tier 3D printing technology to bring their ideas to life, faster and more efficiently.
How Ultimaker and MakerBot Elevate the Challenge
Ultimaker and MakerBot, two of the most trusted names in 3D printing, are bringing their expertise and industry-leading technology to Make48. Participants will have the opportunity to utilize makerbots precise and user-friendly 3D printers, and 2 engineering mentors from Ultimaker’s team to help guide participants with tips and tricks when using the 3D printers. With these advanced tools at their disposal, teams can turn ideas into reality faster than ever before.
The Impact of This Partnership
By sponsoring Make48 we’re investing in the future of design, engineering, and manufacturing. This competition provides an invaluable learning experience, teaching participants about rapid prototyping, iteration, and the importance of creative problem-solving. Equipping the participants with the skills and confidence to bring their ideas to life will encourage the next generation of entrepreneurs and product developers to bring their ideas to market. This is also a great opportunity for educators to see the real impact tools like 3D printing can have in real time and to encourage access to STEM tools in their institutions.
Join Us for an Exciting Year of Innovation
Make48 2025 is set to be an incredible experience and opportunity to its participants. As a sponsor, Dynamism is proud to be part of this journey, empowering makers to push the boundaries of innovation. Stay tuned for event updates, behind-the-scenes insights, and highlights from the competition. Follow make48 on social media @gomake48 and visit the make48 website to learn more about this exciting program.
FDM Printing in Architecture, Design, and Traditional Engineering: Dynamism & Ultimaker Shine at Dubai Design Week
How FDM Printing is Revolutionizing Architecture and Design
Dubai Design Week, the Middle East’s premier design event served as the global stage for Mitsubishi Estate’s visionary 3D-printed teahouse. This groundbreaking creation seamlessly merged traditional Japanese culture and heritage with FDM 3D printing technology, offering a captivating showcase of architectural innovation. Dynamism played a key role in supporting the 3D printing of teahouse components, which were all done using a wood-based filament. These parts were then shipped to Dubai, where they were seamlessly assembled into the stunning final structure.
Dubai Design Week: A Global Hub for Creativity
Dubai Design Week is renowned for uniting designers from around the world to inspire creativity and foster innovation. The annual event features exhibitions, pop-ups, installations, and talks that engage professionals, media, and design enthusiasts while strengthening Dubai’s reputation as a vibrant design capital.
The 3D-Printed Teahouse: Tradition Meets Innovation
The 3D-printed teahouse stood out as a beacon of innovation at Dubai Design Week. By merging traditional architecture with modern 3D printing, this ambitious project showcased how additive manufacturing can preserve cultural heritage while pushing the boundaries of design and engineering.
Traditional Japanese Engineering Influences
The teahouse design drew heavily from Japanese traditions, particularly the “hozo tsugi” joinery technique. This ancient method involves interlocking wooden joints without nails or screws, a skill-intensive practice that ensures durability and elegance. To recreate this authentically, Polywood—a wood-infused resin filament—was used to replicate the aesthetic of traditional Japanese tea rooms.
Ultimaker’s Role in Precision Printing
Key to the project’s success was Ultimaker’s S series 3D printers. Using digital renderings, the intricate teahouse design was divided into 988 individual parts, including 1,938 meticulously crafted “hozo” joints. The Ultimaker printers delivered unparalleled precision, completing approximately 4,000 hours of printing to bring the project to life. The printers’ versatility enabled the seamless integration of traditional engineering with advanced FDM printing techniques.
The Significance of the 3D-Printed Teahouse
The teahouse was more than an architectural marvel—it symbolized the harmonious blending of tradition and technology. Leveraging FDM printing, this demonstrated the transformative potential of additive manufacturing to preserve and reimagine cultural heritage. The teahouse captivated a global audience, underscoring the possibilities of 3D printing in architecture, design, and engineering.
Bridging Heritage and Innovation
Dynamism’s contribution to Dubai Design Week highlighted the growing role of 3D printing in modern design. Projects like the 3D-printed teahouse not only showcase the technological capabilities of FDM printing but also emphasize its power to honor and elevate tradition. As a leader in advanced 3D printing solutions, Dynamism continues to inspire by merging the past with the future through innovative designs.
ColorFabb 2.85mm Woodfill – 600g
Ultimaker S Series
Tullomer: The Ideal Low-Outgassing Filament for UHV Applications
With its remarkably low outgassing properties, Tullomer outperforms standard materials like PEEK, making it ideal for UHV applications. Extensive testing, including residual gas analysis, has proven its reliability in maintaining pristine vacuum conditions, making it a top choice for industries like aerospace and semiconductor manufacturing.
When designing components for ultra-high vacuum (UHV) applications, the choice of materials is crucial. Metals and ceramics have traditionally been favored due to their low outgassing properties, but recent advances in 3D printing are bringing plastics into the conversation. Evaluating these 3D-printed materials, particularly in terms of outgassing and residual gas analysis (RGA), is essential to ensuring they can maintain the integrity of a UHV environment.
Outgassing Challenges in UHV Applications
Outgassing refers to releasing trapped gasses from a material when exposed to vacuum conditions. 3D-printed plastics often present challenges due to the nature of polymer absorption and their manufacturing process, which can leave microscopic voids and unreacted compounds. For 3D-printed plastics to be viable for UHV applications, their outgassing properties must be minimized. Common strategies for reducing outgassing include baking components in a vacuum oven and applying specialized surface coatings.
Residual Gas Analysis and Testing Results
Residual Gas Analysis is a critical process used to evaluate the suitability of materials for UHV applications. By measuring the gases released from a material in a vacuum, RGA allows engineers to detect contaminants and the material’s overall outgassing characteristics. In tests, Tullomer filament has shown a significantly lower emission of residual gases, making it a top choice for environments where even trace contaminants can cause issues.
Tullomer’s Superior Outgassing Performance
Tullomer filament has been scientifically proven to significantly outperform other materials in minimizing outgassing. In a recent study conducted by Lund University, Tullomer demonstrated an outgassing rate lower than industry-standard PEEK after a standard bakeout process. The results were so impressive that Tullomer reached the system detection limit post-bakeout, making it an ideal choice for engineers and researchers in UHV applications. These groundbreaking findings were presented at the SRI conference in Hamburg, where experts praised Tullomer for its unmatched outgassing performance in vacuum environments. As a result, Tullomer is now considered the top material for applications where maintaining vacuum conditions is critical.
Applications in Aerospace and Semiconductor Manufacturing
The unique formulation of Tullomer filament offers more than just low outgassing. It also provides exceptional strength and thermal stability, making it ideal for high-performance applications in both high-vacuum (HV) and UHV systems. Its low desorption rates ensure that vacuum conditions remain pristine, minimizing contamination risks while ensuring reliable operation over extended periods. Extensively tested and validated by leading experts in vacuum technology, Tullomer is engineered for precision. Whether you’re developing complex components for UHV research or deploying systems in critical environments like aerospace or semiconductor manufacturing, this filament offers unmatched performance, with proven results that set it apart from competitors like PEEK.
Why Tullomer is the Future of UHV-Compatible Filaments?
With the development of advanced filaments like Tullomer, 3D-printed plastics are set to become a reliable choice for UHV applications. While traditional polymers like PEEK and ULTEM have demonstrated solid performance, Tullomer’s revolutionary low-outgassing properties place it ahead of the curve. Its strength, thermal stability, and precision make it an indispensable material for engineers and researchers working in ultra-high vacuum environments. By minimizing outgassing and ensuring high system reliability, Tullomer elevates the standard for vacuum-compatible materials. Whether you’re prototyping or producing critical components, switching to Tullomer offers a new level of performance backed by scientific validation and industry trust.
Tullomer Out Performs All Tested Samples
Tullomer performed significantly better both before and after the bakeout, even reaching the detection limit of our setup for the sample size after the bakeout.
Tullomer vs PEEK
Tullomer vs all samples
Download The Full Case Study Results
Tullomer: Minimize Outgassing, Maximize Performance
Dynamism Is Now Offering Z-Polymers Tullomer Filament
As leaders in the additive manufacturing industry, we are excited to introduce the highly anticipated Tullomer™ Super-polymer Filament from Z-Polymers to customers for the first time in North America. This innovative filament is set to revolutionize the 3D printing industry with its exceptional properties and performance. This material is a pure polymer (no fillers) which provides equivalent properties of polymers with continuous fibers (e.g., carbon, Kevlar, glass) and can also be printed on a range of non-proprietary printers such as the Bambu Lab and Ultimaker printers. To experience the superior quality firsthand, contact us for a print sample and see how Tullomer™ Filament can transform your projects.
Environmentally Friendly
In addition to its outstanding performance, Tullomer Filament is also an eco-friendly choice. It is completely PFAS free, fully recyclable, and has an eco-friendly manufacturing process that uses less energy and creates less waste than other materials with similar properties.
Unmatched Quality and Performance
Z-Polymers’ Tullomer Filament stands out in the market due to its superior combination of properties: strength, rigidity, Stable CTE, inertness, non flammability etc., and ability to run on a wide variety of non-proprietary printers. Designed for professional applications, Tullomer Filament offers a unique combination of high strength/stiffness, non-corrosive, non-flammable, extremely high chemical resistance, very low moisture absorption, high thermal performance and low dielectric material properties and RF Transparency.
About Z-Polymers
Z-Polymers is a leading materials science company which manufactures high-performance 3D printing materials and fibers with a focus on innovation and sustainability, Z-Polymers develops cutting-edge filaments that meet the needs of today’s most demanding applications.
Mike Zimmerman, PhD
CEO/Founder
Z-Polymers Inc.
Douglas Krone
CEO/Founder
Dynamism Inc.
Contact Information
2950 W Chicago Ave Chicago, IL 60622
Email: karolina.m@dynamism3d.com | Phone: 1-800-711-6277
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Tullomer Case Study
