Stereolithography and related resin processes cure liquid photopolymers with focused light to build fine features, while fused deposition modeling extrudes molten thermoplastic filament to form layers. Ian Gibson at Deakin University explains in the textbook Additive Manufacturing Technologies that the polymerization chemistry behind resin printing enables smaller feature sizes and smoother surfaces than extrusion methods. This difference in mechanism makes resin printers particularly suited for parts where detail and surface finish are critical, whereas FDM excels at larger, cost-sensitive prototypes and functional parts made from a variety of thermoplastics.
Material and process differences
Resin prints often exhibit higher dimensional accuracy and impressive detail because each cured voxel is formed by directed light, yet the resulting thermoset parts tend to be more brittle and require careful post-curing and washing. Terry Wohlers of Wohlers Associates reports that industry adopters choose resin systems when precision outweighs raw toughness. Fused filament fabrication offers broader material choices such as PLA and ABS with generally better impact resistance, but layer-to-layer adhesion remains a key limiter for isotropic strength and surface smoothness according to academic analyses.
Applications and impacts
Dental laboratories, jewelry workshops and miniature model makers have embraced resin technology for its ability to reproduce intricate anatomy and ornamentation, as observed by Max Lobovsky at Formlabs in company technical guides and case studies. The widespread uptake in these cultural and artisanal niches alters local supply chains by enabling small studios and clinics to produce custom pieces on demand, reducing lead times and shifting some production from centralized factories to territorial makerspaces and small businesses.
Environmental and human considerations
Resin workflows introduce handling, health and disposal implications because uncured resins are chemically active and require controlled post-processing; manufacturers and researchers emphasize ventilation and proper waste management. Joshua M. Pearce at Michigan Technological University has highlighted that thermoplastic extrusion presents different environmental trade-offs, including opportunities for filament recycling and community-level material reuse. The comparative balance between resolution, mechanical behavior, cost, and safety determines which technology a workshop, laboratory or industry adopts, shaping local economies, craftsmanship practices and environmental footprints.
