At M5D, we know 3D printing is about delivering results that are strong, fast, consistent, and cost-effective.  That's why we've partnered with Formlabs, whose latest ecosystem—from materials to machines—is built to solve the most common bottlenecks in modern additive workflows.

Here's how: 

Material Library: Expand Your Possibilities

Current problems:

• Parts fail to meet performance expectations due to limited material capabilities
• You're forced to turn away projects you don't have the right materials
• Outsourcing specialty parts adds cost, delays, and risks
  
  

Solution:
Formlabs offers one of the most diverse resin and powder portfolios on the market—from engineering-grade nylons to biocompatible, flexible, and heat-resistant resins.  Print prototypes, tools, and end-use parts all in-house, and take on more projects without hesitation.  Even supports Open Material Licensing on Form 4 and Form 4L.

The largest selection of resin and powder-based materials in the industry are at your fingertips.
The booklet for all their materials is down below.

Formlabs Material Library.pdf

Form 4 / 4L: Speed, Reliability, and Flexibility

Current problems:

• Long print times delay innovation and delivery.
• High outsourcing and material costs eat into your margins.
• Inconsistent quality and part failures impact trust.
• Limited build volumes restrict part size and throughput.

Solution:
The Form 4 and Form 4L combine blazing-fast print speeds, automated resin management, and precision optics to deliver high-quality parts in less time—with build volumes to match your ambition.  Reliable, scalable, and ready to grow with you.

Check out the following pdfs on our 3D resource page:  Form 4L vs Form 3L & Form 4

Fuse 1+ 30W: Industrial-Grade SLS, Reimagined

Current problems:

• Weak or fragile prototypes that don't survive real-world use.
• Inconsistent results make it hard to scale or standardize.
• Production grade applications cannot be pursued because of expensive equipment.
• Wasted powder and limited in-house capabilities force outsourcing.

Solution:
The Fuse 1+ brings production-ready SLS printing to your workspace—with powerful lasers, recyclable materials, and a compact footprint.  Durable parts, repeatable results, and an ecosystem (Fuse Sift & PostFuse) that's built for true in-house manufacturing.  The most ground-breaking part of the system is that the investment starts as low as $20,000.

Check out the following pdfs on our 3D resource page: Fuse 1 Ecosystem pdf

Automation: Less Hassle, More Output

Current Problems:

• Time-consuming post-processing slows your team down.
• Manual resin handling and material changes lead to delays.
• Powder handling is messy and inefficient.
• Tracking consumables and usage becomes guesswork.

Solution:
With automated resin dispensing, powder recovery, material detection, and workflow integration, Formlabs systems are designed to reduce manual steps and maximize output. You focus on creating—the machines handle the rest.

View the following pdfs on our 3D resource page: Fuse 1 Ecosystem, Form 4 & 4L Ecosystem, & Resin Wash  

Ready to Level Up?

If these problems sound familiar, you're not alone—and you're not stuck.  With this partnership with Formlabs, a comprehensive digital manufacturing solution and technology-focused adoption team is available to tackle these exact problems.

Read more about Formlabs partnership or talk to me, Zach Carr, about how to bring this technology in-house.

Zach Carr
zcarr@m5d.com
(312) 982.4268

That question came from Shane Jetton during a conversation—and it stuck with me.  In an industry full of big promises and even bigger price tags, it's a fair question to ask.  At M5D (formerly MasterGraphics), we've been deeply involved in metal additive manufacturing for years.  And like many others in this space, we've made some expensive mistakes—investing in systems that didn't live up to the hype.  So when One Click Metal approached us about becoming a reseller,  our initial reaction was skepticism.  Affordable DMLS printing with industrial-grade output? It sounded like another lofty promise. But after doing the research—speaking with other resellers, end users, and evaluating their product line—we decided to move forward.

One Year In:  One of Our Best Decisions in Additive Manufacturing

Now, nearly a year later, we've installed over 10 One Click Metal systems across a range of customers—from small shops to enterprises.  And we're confident in saying this was one of the two best AM decisions we've made in the last decade (the other being HP in 2017).

Here's why:

1. Simplified & Safer Powder Handling

One Click's cartridge-based powder management system drastically reduces direct interaction with metal powders, improving both safety and cleanliness on the shop floor.  The integrated MPURE station automates depowdering and sieving, making unused powder easy to recycle and reuse—a crucial feature for cost control and sustainability.

2.  Industrial-Grade Hardware in an Accessible Package

Despite its compact size and lower price point, the MPRINT+ system is packed with serious performance:

• 200W Fiber Laser
• Galvo Scanner with scan speeds up to 3000 mm/s
• Focus diameter of 45 microns
• Build Volume of 150 x 150 x 150 mm

This makes the system ideal for both prototyping and low-volume production.

3. Cost-Effective and Scalable

Lead with price?! I always believe that any solution needs to start wit the "pain" first to see if there is even a solution.  The clear ground breaking part of the system is a total system price around $200,000, One Click offers a far more accessible entry point into metal AM compared to traditional DMLS systems, which often exceed $800k.

Want to break it down even further?  You're looking at about $5K/month, including equipment and maintenance.   That's a very manageable entry point—and a strong starting ROI for SMBs, service bureaus, or educational institutions.  

4. Modular Design for Future-Proofing

The BOLDSERIES platform includes:

• MPRINT+ Printer
  • Ask me about the lab print module - an innovative way to run different materials!
    
• MPURE Processing Station
• MONE 3D Print Software

This modular ecosystem makes upgrades and servicing far more manageable, ensuring that customers can scale their system as their needs evolve.

5. Remote Monitoring & Control

Through the MONE software, users can remotely control and monitor print jobs from anywhere—ideal for busy teams or distributed production environments.

Real-World Performance: Side-by-Side with the Big Guys

We've installed One Click systems alongside legacy DMLS systems that cost nearly four times as much—and the results are comparable.  That's not just a selling point, that's proof.  While no system is perfect—and One Click continues to improve, especially in their OS—we're confident in the solutions.  So confident, in fact, that we've personally guaranteed success to our customers.  

Final Thoughts

If you've been skeptical of metal AM systems, you're not alone.  If you've been burned in the past, we've been there too.  But the One Click Metal system is the real deal:  safe, scalable, and affordable—without sacrificing performance.  So, can you trust a $200K DMLS system?

Yes—you can!

And we believe it's changing the landscape of metal 3D printing.

If you'd like to see it in action, learn more, or talk to other customers, we'd be happy to connect you with the right people—even if you're outside our region.

M5D One Click Metal webpage

Thanks for reading!

Kevin Carr
President | M5D
kcarr@m5d.com

M5D will be hosting a seminar on Additive Manufacturing during the Annual SPE Thermoforming Conference.  This conference is dedicated to educating attendees on the development and application of thermoformed products, covering both thick and thin gauge materials.

The Additive Manufacturing track will focus on how digital manufacturing technologies are being integrated into the thermoforming industry.  Attendees will learn how these innovations can accelerate time to market, reduce costs, expand manufacturing capabilities, and support creating more cohesive production systems.  

The seminar will feature the following presentations:

1. Large-Format Printing with the Titan Pellet Extruder by 3D Systems
   This session will explore how large-format 3D printing is being used to produce thermoforming molds across various industries.  A featured case study will showcase a motorcycle fairing made from thick-gauge material, with intricate backside details created using 3D Systems' PSLA process.  The components were assembled using adhesive bonding, highlighting benefits such as faster lead times and cost savings.
2. Polypropylene (PP) Printing and Assembly with Forecast 3D
   This presentation will demonstrate how Forecast 3D leverages PP-based additive manufacturing to create detailed components for assemblies.  These parts are designed to integrate with PP-based materials like TPO and enable traditional plastic welding methods.  The process supports efficient digital manufacturing while maintaining compatibility with existing thermoplastic joining techniques.
3. Tooling with Binder Jet Sand Printing by Catalysis 3D
   Catalysis 3D will showcase how binder jetting with sand can produce high-performance thermoforming tools.  This approach results in durable molds with improved thermal characteristics and rapid development timelines, offering a cost-effective alternative to conventional tooling methods.

To conclude the seminar, I will present on Adding Value to Products Through Digital Manufacturing.  My talk will examine how emerging technologies evolve into essential enablers, focusing on the strategic benefits that digital manufacturing can bring to a product portfolio.

Click here to register for the 2025 SPE Thermoforming Conference in Atlanta, Georgia May 19-21, 2025 

Could you elevate your Approach with a Solid Plan from the Experts?

Challenge the status quo by asking yourself: Is your current additive manufacturing plan truly optimized, and how can you elevate it to new heights of success? 

Please prepare for enlightening insights as our experts share their valuable knowledge.

You'll hear from 4 expert panelists:

• Carl Douglass, CEO, DI Labs
• Brian Douglass, COO, DI Labs
• David Rosendahl, President & Co-Founder, MindFire Inc
• Kevin Carr, President, MasterGraphics

In this session, our panelists will analyze and exchange insights on:

1. How embracing Additive Manufacturing can reshape your product development approach, fostering agility and sparking creative ingenuity.
2. Why having a structured process for product development through Additive Manufacturing is not just advantageous, but essential.
3. How aligning your additive manufacturing strategies with your business goals can drive growth, boost efficiency, and amplify your competitive edge.

Whether you're a business owner, product manager, or industry professional, this webinar offers valuable insights and practical strategies for anyone seeking to enhance their additive manufacturing prowess.

Watch Video

What you'll learn...

Uncover the transformative power of 3D printing in our webinar.  Learn how it drives revenue growth, revolutionizes product development, and enhances the customer experience.  Unlock the immense potential of 3D printing for growth and innovation in your business.

You'll hear from:

• David Tucker, Business Development Consultant, New Wave Manufacturing
• Carl Douglass, CEO, Di Labs
• Kevin Carr, President, MasterGraphics
• David Rosendahl, President, MindFire Inc., Moderator

In this session, our panelists break it all down and discuss:

1. What the terminology "solutionologist" means.
2. How to leverage additive manufacturing through a product development process beyond simple prototyping.
3. Where they see the largest opportunity for additive in developing new product portfolios.
4. David explains his customized innovation workshops that empower customers to maximize the potential of additive manufacturing.
5. The term, "creating a digital product portfolio", really means.

In the webinar, we addressed attendee questions on the potential and impact of additive manufacturing in manufacturing and businesses, while also exploring solutions to address customer challenges.

Watch this webinar recording now to start off on the right foot and get answers to questions you may have or may have not even thought of!

Watch Video

What you’ll learn…  

In the third panel discussion of our three-part series, you’ll get answers to key questions from three additive manufacturing leaders who don’t shy away from the truth and have critical insights to share.  

You’ll hear from:  

• Kevin Carr, President, MasterGraphics
• David Tucker, Business Development Consultant, New Wave Manufacturing
• Michael Rosplock, Manager of Digital Manufacturing, Enerpac
• David Rosendahl, President, MindFire Inc., Moderator  

In this session, our panelists break it all down and discuss what is needed to leverage best-in-class 3D Print manufacturing processes with these five considerations:

1] Why it is imperative to write an effective proposal to convince the required executives and the technical team that new 3D print technology is a worthy investment. The need to justify the expenditure. 

2] The importance of designating a project lead and the value they bring to achieving effective implementation. 

3] The project leader's ability to focus on part development that leverages the additive manufacturing cell effectively. 

4] The need for understanding the proper AM cell setup and the expected production processes. 

5] The key to success also includes focusing on the factory blueprint layout that outlays the physical workflow from print to finish.

Watch this webinar recording now to start off on the right foot and get answers to questions you may have, or may have not even thought of!

What you'll learn...

In the second panel discussion of our three-part series, you'll get answers to key questions from three additive manufacturing leaders who don't shy away from the truth and have critical insights to share.  

You'll hear from:

• Kevin Carr, President, MasterGraphics
• Dennis Richards, CO, Certified Orthotist, 3D Stability
• Vince Anewenter, Director of Rapid Prototyping Consortium, Milwaukee School of Engineering
• David Rosendahl, President, MindFire Inc., Moderator

In this session, our panelists break it all down and discuss:

1) Why now IS the right time to invest in additive manufacturing and restore your supply chain (in the face of a looming recession).

2) Surefire ways to find and land profitable opportunities, assess cost-effectiveness and prove the value of AM.

3) The best ways to avoid common startup challenges and set yourself up for success.

4) How learning to design for AM will enable you to maximize your capabilities and profit.

5) Determine when/how to bring AM in-house and what to consider once you do!

Does the looming recession have you worried? Confused about the path forward for your business? Or terrified to make a costly misstep?

If so, you're not alone.  Many companies are turning to additive manufacturing as a solution—and you can, too!  But in order to optimize your success with this technology, you'll need to know where to start and what steps to take to set yourself up for success.

Watch this webinar recording now to start off on the right foot and get answers to questions you may have, or may have not even thought of!

A common question I hear from my customers is, "What 3D materials are tough and which materials are best suited for certain applications?"  The second question I typically hear is, "What is the print speed?"  While not many new AM technologies are being developed, the same is not true with materials.  With innovations in 3D printing and materials development, entirely new business models are being unlocked.  3D printing is developing fast.  With ever-evolving technologies and materials, the range of addressable applications across industries has never been so varied or offered such huge opportunities.  No material can do everything.

The 3D Systems' Figure 4 DLP technology has been especially transformative.  Innovative new materials open up new production workflows for digital manufacturing.  Plastic printing materials are particularly versatile.  Listed below are industrial materials and applications applicable to the Figure 4 DLP technology.  These materials are a new class of additive materials with industry-leading UV stability.

Figure 4® Rigid 140C Black, Figure 4® Rigid White, Figure 4® Rigid Gray, Figure 4® Tough 60C White, Figure 4® Tough 65C Black, Figure 4® PRO-BLK 10: True production-class material; versatile rigid urethane-like material with an industry-leading combination of speed, accuracy and engineering-grade properties of strength, impact, and heat resistance.
GOOD FOR:  • Rapid prototyping • Functional assemblies • Snap-fit components • Consumer electronic components • Drill/tap applications • Master patterns for vacuum casting

Figure 4® 150C FR Black: 
GOOD FOR: • Aircraft interior parts • Consumer goods and electronics • Components requiring flame retardancy

Figure 4® FLEX-BLK 20 and Figure 4® FLEX-BLK 10: Extremely durable polypropylene-like parts Highest precision prototyping material with UV stability for production applications where mechanical properties fit.
GOOD FOR: • Prototyping • Functional testing • Low-volume production • Master patterns for RTV/silicone molding • Snap-fit assemblies

Figure 4® HI TEMP 300-AMB: High-temperature resistance for use in the harshest environments.
GOOD FOR: • HVAC, consumer appliances, motor enclosures, and other test or end-use components requiring high heat resistance • Low-pressure molding/tooling • Overmolding

Figure 4® RUBBER-BLK 10 and Figure 4® Rubber 65A BLK: High tear strength, malleable material for hard, rubber-like parts.
GOOD FOR: • Functional prototypes with rubber-like properties - Gaskets - Hoses - Seals • Low to mid-volume direct manufacturing of end-use parts • Strain-relief applications

Figure 4® MED-AMB 10 and Figure 4® MED-WHT 10: Materials with biocompatibility and autoclave stability for medical and industrial.
GOOD FOR: • Medical applications, including - Surgical drill guides - Splints - Anatomical or bone models • High-temperature applications

Figure 4® EGGSHELL-AMB 10: A rigid plastic for casting silicones to withstand injection at high temperature and pressure, but easy to break away. 
GOOD FOR: • Silicone castings • Customized end-use silicone parts • Low-volume production of silicone parts

With a better understanding of industrial materials discussed for the 3D Systems' Figure 4 DLP technology, I want to discuss the advancements in print speed.  Figure 4 offers ultra-high print speeds with 3 print modes, enabling up to 100mm/hour printing, some of the faster on the 3D printer market today.  The following is a good example from a service bureau printing aerospace check fixtures.  

• CHALLENGE: Deliver production-grade check fixtures for aerospace customer with a very fast turnaround.
• SOLUTION: Figure 4 with 3D Sprint software and Figure 4 TOUGH-GRY 15 material.
• RESULTS: 
  • 24 parts printed per tray
  • Print set up time - 7 minutes
  • Time to part in-hand - 91 minutes
  • Print time - 31 minutes
  • Post-processing - 60 minutes

To round out the key advancements of the 3D Systems' Figure 4, alongside the materials science and production-grade end-use parts at accelerated speeds, the new high-density part stacking feature of 3D Systems' 3D Sprint software allows efficient part nesting and optimized support generation to enable new efficiency in batch printing and post-processing.  Advantages of High-Density Vertical Stacked Printing over traditional methods 3D printing often leads to fast turnaround times without using expensive tooling.  Additive Manufacturing, AM serves as a great tool for prototyping and low/mid-sized production by using high-density vertical stacked printing.  Key drivers for stacked printing include:

• Productivity and Efficiency: by utilizing the full build height (350 mm) and stacking parts, more parts can be printed.  With 3D Systems' additive manufacturing workflow software, 3D Sprint, stacks can be easily generated and supported to maximize packing density, reduce post-processing, and decrease labor times.
• Strut Array Generation:  Quickly generate and replicate strut supports throughout a stack within 3D Sprint.  The open, sparse strut network maximizes solvent washing, air drying, and post-cure process effectiveness for batch manufacturing.
• Overnight Printing and Cadence: For manufacturers that do not work around the clock, there is a lot of wasted time at night that could be used for printing parts.  Prints can be planned more efficiently to improve throughput in a single day by printing less frequently, but with a larger yield.  If build times are too short, technicians would get overwhelmed from replacing builds for many printers.
• Automation Compatible: Another method for improving the efficiency of the entire workflow is by using automation.  With pinpoint contact strut supports allowing for quick removal of supports, automation can be used to clean, dry, and cure stacks of parts without human labor.  Multiple wash stations can be used for cleaning parts.

If you want to know more about the advancements of vertical stacking with the 3D Systems solutions please click the following: 3D Systems Application Brief - Industrial Stacking

If you want more information in general, feel free to visit us at www.mastergraphics.com or contact me directly at barb.miller-webb@mastergraphics.com

If you’re like most businesses, you’ve got numerous questions about additive manufacturing—perhaps even a few misconceptions, too. You’re wondering: 

• Why should I be excited about adopting additive manufacturing?
• Can it really provide a competitive advantage?
• How would it help solve my customer challenges?
• What if it doesn’t work for me?

We created this webinar to answer these questions and many more.  

In the first of our three-panel discussions, you’ll hear from additive manufacturing leaders who will answer these questions and MORE—all from their own experience. How they started. What they learned. What mistakes to avoid.
You’ll hear from:

• Peter Koostra, Director of Engineering, RE3DTECH
• Kevin Carr, President, MasterGraphics
• David Rosendahl, President, MindFire Inc., Moderator

Watch the webinar recording now to gain insights into:  

• The unexpected reasons organizations are adopting additive manufacturing for a competitive advantage
• How companies start their additive journey (often through diversification), and the surprising lessons learned along the way
• Which approach to additive manufacturing doesn’t work
• Answers to questions that our webinar attendees had about expanding solutions to customers’ challenges