Magna International chooses the Form 3L for prototyping large parts

Magna International stands out as a forward-thinking company, passionately dedicated to delivering innovative mobility solutions for automotive manufacturers. With a workforce of 157,000 strong, the company’s influence can be seen in most vehicles on the road today.

This widespread impact stems from its impressive network of 344 manufacturing facilities and 93 product development centers spread across 27 countries. Among the talented professionals driving this innovation are Robert Esser and Mitchell Wesley, key contributors to Magna’s product development team. Their expertise spans all mirror divisions, playing a valuable role in shaping the future of automotive technology. In this feature, they delve into how 3D printing has become a cornerstone of their work process and share the reasoning behind their recent decision to expand their capabilities with the addition of a Form 3L printer.

From Form 3 to Form 3L

Vehicles are made up of thousands of parts, from small sensors to large body components. Like many automotive companies, Magna International uses 3D printers to help them design and prototype these parts. Over time, they expanded their fleet beyond Fused Deposition Modeling (FDM) printers, adding Formlabs stereolithography (SLA) printers, primarily to access the printer’s wide range of technical materials. The Form 3 was used in many projects, but some parts were too bulky to fit on the Form 3 build bed.

For this reason the team decided to purchase a Form 3L. With the Form 3L, the team had access to a build platform five times larger than the Form 3, while maintaining access to a range of engineering resins such as Rigid 10K Resin, a material designed for precision industrial parts that must withstand significant pressure without bending. Large format printing comes as a complement to their current capabilities. The ability to print parts at the same quality as the Form 3, but 5 times larger, will expand the team’s capabilities. And because the Form 3L supports many of the same resins as the Form 3, the team already knows they can create the solid, reliable parts their designs require.

Adding the Form 3L to their existing Form 3 fleet was easier than they expected. The Form 3L uses the same print preparation software, PreForm, as other Formlabs printers, meaning teams already using the Form 3 can easily load pre-existing software and start printing.

“We were also impressed with the design of the Form 3L. We have customers come into the factory and we love showing them the 3D printing room. From the LED light strips to the case that closes the machine, the first impression is fantastic.” -Mitchell Wesley

Conclusion

The decision by the team to procure the Form 3L represents a highly rational and strategic expansion of their existing additive manufacturing capabilities. This acquisition’s most significant benefit is the five-fold increase in build volume, immediately addressing limitations in printing large industrial components as single pieces. Critically, this size increase does not compromise the high standard of precision and detail established by the Form 3, nor does it necessitate the abandonment of trusted materials.

The large-format printer’s compatibility with high-performance resins, such as Rigid 10K Resin, ensures that the newly expanded capabilities are directly applicable to the production of solid, reliable parts capable of withstanding significant industrial pressure. Operationally, the transition was made seamless and highly efficient due to the shared PreForm software and resin ecosystem across the Formlabs fleet. This plug-and-play integration minimized training time and workflow disruption. Furthermore, the modern and impressive design of the Form 3L contributes positively to the team’s professional image, serving as an effective visual showcase for clients. Ultimately, the Form 3L is not just a larger printer; it is a complementary technology that significantly amplifies the team’s capacity for in-house manufacturing, allowing them to tackle bigger, more challenging projects with proven quality and efficiency.