Quick Listen:
At CES 2023 in Las Vegas, amid the clamor of futuristic tech and sleek prototypes, a quieter but no less transformative unveiling took place. Formlabs, the Somerville, Massachusetts-based pioneer in 3D printing, introduced its Automation Ecosystem, a system designed to overhaul how industries produce everything from medical devices to automotive components. Far from a niche gadget, this is a bold leap toward “lights-out” manufacturing factories that hum with activity long after workers have gone home. In an era where efficiency and scalability are paramount, Formlabs is positioning its latest innovation as a cornerstone of the smart factory revolution.
The Automation Ecosystem is a trifecta of hardware, software, and material advancements that together enable continuous, high-volume 3D printing. At its core is Form Auto, a device that automatically removes finished parts from the printer bed using patented Quick Release Technology, seamlessly queuing the next job. Fleet Control software orchestrates multiple printers, managing print schedules and materials with precision akin to a digital conductor. The High Volume Resin System, meanwhile, expands resin capacity fivefold, ensuring printers stay operational for extended runs. Formlabs claims this system can reduce labor costs by up to 80%, lower per-part costs by 40%, and cut packaging waste by as much as 96% figures that underscore its potential to reshape manufacturing economics.
The global 3D printing market, valued at $24.61 billion in 2024, is on track to reach $134.58 billion by 2034, growing at a robust 18.52% annually, according to industry projections. Within this, the automated 3D printing segment is poised for explosive growth, expected to surge from $2.91 billion in 2025 to $13.77 billion by 2030, fueled by demand for bespoke products in healthcare, automotive, and aerospace. Founded in 2011 by three MIT Media Lab graduates, Formlabs has long been a trailblazer, posting $82.5 million in revenue in 2021 and democratizing 3D printing for industries worldwide. With the Automation Ecosystem, the company isn’t just riding the wave it’s steering the ship.
The Rise of Autonomous Manufacturing
Step into a conventional factory, and you’ll find a hive of activity: workers adjusting machines, moving parts, and troubleshooting hiccups. Now envision that same space, silent and dark, yet producing at full capacity. This is the essence of “lights-out” manufacturing, a growing trend as industries embrace automation to maximize output and minimize costs. The Automation Ecosystem meets this demand head-on, integrating hardware and software to keep 3D printers running 24/7. “This is a seamless solution for scaling production with printer fleets, designed for ease of use so anyone can create anything,” said Dávid Lakatos, Formlab’s chief product officer.
What sets this system apart is its synergy with the Industrial Internet of Things (IIoT), the network of interconnected devices driving smart factories. Fleet Control’s API integrates with manufacturing execution systems (MES) and enterprise resource planning (ERP) platforms, enabling real-time monitoring and control from anywhere in the world. This isn’t merely about speed it’s about intelligence. By automating repetitive tasks like part removal and print scheduling, the ecosystem frees workers to tackle high-value activities, such as product design or material innovation. It’s a vivid illustration of Industry 4.0, where data and automation converge to redefine production.
Real-World Impact Across Industries
The ecosystem’s true power shines in its applications. In dental labs, where demand for custom implants and surgical guides is relentless, Formlab’s system allows technicians to scale output without expanding staff. A fleet of Form 3+ or Form 3B+ printers can produce parts overnight, cutting labor costs and accelerating patient care. In the automotive sector, manufacturers leverage the system for rapid tooling and concept models, ensuring production lines stay active even during off-hours. The inherent flexibility of 3D printing ideal for small-batch, customized parts makes it a perfect match for these industries, and Formlab’s automation amplifies its impact.
A standout example is Formlab’s collaboration with New Balance, where the company developed Rebound Resin for high-performance athletic footwear. The Automation Ecosystem enables New Balance to produce shoe components at scale, iterating designs swiftly without disrupting workflows. This partnership highlights a broader truth: automation doesn’t just streamline processes it catalyzes creativity. By offloading routine tasks, the system empowers companies to explore new materials and designs, pushing the frontiers of 3D printing’s potential.
Hurdles on the Horizon
Despite its promise, the Automation Ecosystem isn’t without limitations. It’s compatible only with Formlab’s newer models Form 3, Form 3+, Form 3B, Form 3B+, Form 3L, and Form 3BL excluding users of older Formlabs printers or competing brands. The High Volume Resin System, while a boon for capacity, is restricted to specific resins, potentially limiting options for specialized applications. Additionally, while Formlabs emphasizes user-friendliness, integrating the system into complex IIoT environments may demand training, particularly for smaller operations. These constraints could temper enthusiasm for startups or niche manufacturers.
Efficiency, Innovation, and Sustainability
The benefits, however, are compelling. Formlabs reports that the ecosystem can triple productivity, enabling printers to run continuous jobs without human intervention. This is a game-changer for small and medium-sized manufacturers, who can scale operations without proportional increases in labor costs. The financial impact is striking: up to 80% savings on labor, 40% reductions in per-part costs, and a 96% drop in packaging waste. In an age where sustainability is both a priority and a mandate, the system’s ability to minimize waste and localize production aligns with the push for eco-conscious manufacturing.
Beyond cost savings, the ecosystem unlocks human potential. With automation handling mundane tasks, engineers can focus on research and development, crafting innovative designs or optimizing materials for superior performance. This creates a feedback loop: efficiency drives innovation, which in turn fuels further automation. The IIoT integration enhances this cycle, providing managers with real-time data to make informed, strategic decisions a hallmark of the smart factory.
A Vision for the Future
Wandering the CES 2023 floor, I watched Formlab’s printers operate with mechanical precision, producing parts without a human in sight. This wasn’t just a product debut it was a declaration of intent. The Automation Ecosystem cements Formlabs as a leader in the next industrial era, where data-driven, automated factories redefine what’s possible. Looking forward, Formlabs is likely to deepen IIoT integration, broaden its material offerings, and potentially expand compatibility to include more printers. For now, this system marks a significant stride toward a manufacturing future that’s faster, more cost-effective, and environmentally responsible.
For manufacturers, the call to action is clear: evaluate the Automation Ecosystem for its potential to transform high-throughput operations, particularly in dental, automotive, or medical sectors. For IIoT specialists, the system’s API offers a sandbox for building sophisticated, factory-wide automation. And for R&D teams, it’s an opportunity to accelerate prototyping and material breakthroughs. As Lakatos aptly stated, this is about enabling anyone to create anything, anywhere, anytime. In a world that never stops, Formlabs is delivering the tools to keep pace.
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