When developing the Form 4 printer, Formlabs faced a familiar challenge for any fast-moving hardware company: the need to keep development momentum high, without getting bogged down by long lead times from external vendors. For a company known for pushing the boundaries of resin 3D printing, waiting weeks for outsourced parts just wasn’t an option. That’s where the Mayku Multiplier came in—a pressure former that’s become a cornerstone of Formlabs’ prototyping workflow, giving their team the speed and control to prototype thermoformed parts in-house.

About Formlabs R&D: A Hub for In-House Innovation

Formlabs has always placed a strong emphasis on in-house prototyping, and their Boston headquarters is a testament to that philosophy. The R&D machine shop is fully equipped for rapid development, with water jetting, CNC machining, laser cutting, welding, casting, thermoforming, and—of course—their own advanced resin 3D printers. By keeping all these capabilities under one roof, Formlabs engineers can move through every stage of prototyping without outsourcing, maintaining quality and inspection standards, and staying on track with the ambitious timelines that define their development process.

The LPU 4 is a subsystem for Formlabs machines.

Why the Mayku Multiplier?

Thermoforming is a well-established process in engineering, but many traditional machines are outdated, slow, and poorly supported. Setup, operation, and cooling can drag out a project, introducing friction and delays. The Mayku Multiplier changes that with pressure forming technology that delivers high-definition results typically reserved for much larger, more expensive machines.

With the Multiplier, Formlabs engineers have been able to form thin-walled parts with complex geometry and steep draft angles—features that are often out of reach for standard vacuum forming tools. As Franko Kosic-Matulic, Machine Shop Coordinator at Formlabs, explains:
“We can definitely rely on the Multiplier to give us really high detail and also form quickly and produce a lot of parts. Without good tools, it’s hard to stay motivated to prototype thermoformed parts in-house. That friction often pushes engineers toward external vendors. But the Multiplier gives us great results – and we know we can count on it.”

Material heating to temperature.

Frictionless Product Development: The LPU 4 Case Study

A perfect example of this streamlined workflow came during the development of the LPU 4—the light processing unit for the Form 4 printer. Engineers needed a slim, precise cover to protect an IR sensor from resin ingress, a tricky part to manufacture quickly with traditional methods. The risk of sticky resin seeping inside could cause serious damage and cleanup headaches.

With time short and the part requiring both strength and precision, the team leveraged Formlabs’ own 3D printed molds and the Mayku Multiplier. In just days, they prototyped, tested multiple materials, and landed on a solution—all without ever leaving the building.

As Jennifer Lu, Mechanical Engineer at Formlabs, puts it:
“Being able to go from idea to prototype in a day or two changes how we work. It lets us test faster, learn faster, and stay focused on building a better product.”

Multiplier pressure formed IR sensor covers on a Formlabs SLA 3D printed mold.
The finished article after post-processing

Traditional vs. Multiplier: A Workflow Comparison

Agility, Speed, and Innovation

For Formlabs, the Mayku Multiplier is far more than just another machine—it’s a way to stay agile, reduce friction, and keep innovation moving. By bringing advanced thermoforming in-house, the team can quickly respond to design challenges, iterate on ideas without delay, and maintain their focus on building world-class products. In a field where speed, precision, and adaptability are crucial, the Multiplier helps keep Formlabs one step ahead.

Placing tooling on the forming bed of the Multiplier.

Ready to Start Producing Professional Prototypes In-House?

With in-house pressure forming, the Mayku Multiplier allows for quick, cost-effective prototyping. If you’re interested in exploring the benefits of in-house pressure forming, contact a Mayku Expert today.