Selective laser sintering (SLS) has long been valued for the ability to 3D print durable and highly detailed nylon parts that are ready for demanding end-use applications. However, high-quality in-house SLS has been out of reach for most designers due to high costs, large space requirements, and arduous user workflows. The Fuse 1 brings the powerful prototyping and production capabilities of SLS to a broad array of new users with an ecosystem designed to deliver new levels of ease of use, efficiency, and affordability.

Selective laser sintering (SLS) has long been valued for the ability to 3D print durable and highly detailed nylon parts that are ready for demanding end-use applications. However, high-quality in-house SLS has been out of reach for most designers due to high costs, large space requirements, and arduous user workflows. The Fuse 1 brings the powerful prototyping and production capabilities of SLS to a broad array of new users with an ecosystem designed to deliver new levels of ease of use, efficiency, and affordability.

The Fuse 1 selective laser sintering (SLS) process uses laser power to fuse nylon powder into lightweight, durable parts. During printing parts are supported by the surrounding powder, resulting in support-free prints with consistent and clean surfaces. This inherent part support also enables fully unconstrained 3D part packing within the build chamber for maximum throughput efficiency. Nylon is a great material for end-use production-intent parts and the efficiency of Fuse 1 enables designers to move from prototyping directly into production. In fact, Formlabs relies on the Fuse 1 for production, as the Fuse 1 itself is made using a number of SLS parts that are supplied using our in-house production farm.

The hardware design of the Fuse 1 system enables intuitive, safe, and accessible physical experiences for users. Fuse Sift is an automated powder management system aimed at keeping the workflow easy and clean by reducing manual labor and user interaction with powder. The system combines part extraction, powder recovery, storage, and mixing in a single free-standing device. Users extract finished parts on an ergonomic work surface that features task lighting, backdraft vacuum for reduced powder plume, vacuum hose integration, a clear containment hood, and tool storage. The Fuse Sift works together with a sealed Powder Cartridge to enable a closed powder transfer system for reduced effort and mess. To reduce confusion and get users up to speed immediately, the design uses blue accents to call attention to key touchpoints of the physical workflow. This blue callout is also leveraged across the packaging, printed guides, and the UI to emphasize important features.

Driving the Fuse and Sift hardware is a powerful software ecosystem and easy to use interface set apart by 3 unique features: Fuse Vision; Assisted Maintenance; and End to End Powder Management. Fuse Vision allows real-time monitoring and error checking of prints using a robust computer vision and machine learning algorithm that can detect obstructions and artifacts that deviate from the original design. In addition, users can monitor this feed in real-time directly from the printer interface or remotely via PreForm. Assisted Maintenance is a tracking system and contextual instruction UI that keeps track of routine maintenance tasks, alerts and guides users on how to clean optical elements, replace filters, and perform the necessary functions to keep the hardware operating at peak performance. This significantly reduces the normal training associated with operating a SLS 3D printer of this class. Finally, End to End Powder Management gives users fine control of powder refresh rates, allowing them to recycle the vast majority of used powder towards new prints. On-screen controls allows users to track powder volumes and mixed ratios, while controlling dispensing and mixing mechanisms for recycled powder.

Most designers simply do not have the money, space, or staff to run traditional SLS systems. As such, solving these issues and delivering unparalleled value to users has been at the heart of every design decision in the Fuse 1 ecosystem. The designers and engineers developed a highly integrated and tightly packed system to minimize the footprint required for operation in offices and workshops. The Build Chamber is designed to be quickly and easily removed after printing, so a new print can be started right away to eliminate machine downtime for highly cost-efficient production. The Fuse 1 operates with a 30% material refresh rate, meaning you can print with up to 70% recycled powder, indefinitely. This reduces material waste and keeps long-term operating costs low. Most notably, the cost of entry for the Fuse 1 system is drastically lower than machines with comparable print quality.

The Fuse 1 system brings a new and powerful tool to more people than ever before by eliminating traditional barriers to entry. Across hardware and software, the priority on intuitive and accessible design enables new users to be successful and efficient with SLS printing. Whether powering a small business or making production parts at a large corporation, the Fuse 1 ecosystem pushes forward the Formlabs mission of helping anyone to make anything.