Note: Most of our prints were done using an older version of the print design, but the concepts should apply to newer version.
Printers: We've tried both filament (Prusa MK3S) and resin (FormLabs Form2), and had success with both. While I'm not sure I'd only want a resin printer, they make nearly perfect front plates every single print. Filament printers generally require some "fiddling", even a moron like me can get a resin printer to work easily. We haven't found the perfect resin (standard black is easier for mice to chew than filament), but long-term I think this may be a good way forward. We had to make minor modifications to design to make them print properly using resin, and we're happy to upload them to Github or provide them to anyone that would like them. Also happy to provide more details on Tips and Tricks to resin printing FEDS if it would be helpful.
Resolving Issues with Frontplate Prints: I wasn't sure where to put this, but many of our initial FEDS had issues with double-pellets (did not detect the first pellet, so it releases a second one), or less commonly ghosting (pellet well thinks it has a pellet but does not) or . We found that double pellets often occurred when the middle pellet-detector was incompletely blocked by a single pellet, and could be easily fixed by adding a small layer of epoxy to the pellet holder (blue arrow). If we added too much epoxy so that it partially blocked the beam when no pellets were present, it produced ghosting that could be fixed by sanding down the epoxy layer. Using this approach, we have substantially reduced the number of "failed" frontplate prints.