The Fuse 1 is the first SLS-based 3D printer from American manufacturer Formlabs. Known for its SLA Form 1, the Form 1+ and the Form 2 machines, the Boston-based manufacturer decided to embark on the selective laser sintering niche. Despite being announced in 2017, the machine was not officially released to the market until early 2021. SLS technology is normally associated with industrial 3D printers whose selling prices run into the hundreds of thousands of euros. However, Formlabs was looking to offer a high-quality solution at a not-too-high price point. Thus, the Fuse 1 is now available for an entry-level price of €15,000.

Features of the Fuse 1 3D printer

With a hardware size of 1255 x 1495 x 1870 mm and a weight of 114kg, the Fuse 1 is categorized within the family of powder bed based technologies. It features a maximum print volume of 165 x 165 x 300 mm and a layer thickness of 110 microns. In terms of printing materials, Formlabs’ machine is capable of creating parts with polyamides (PA11, PA12) as well as other reinforced thermoplastics, using a 10 Watt Fiber Laser for reliable, in-house 3D printing. In addition, its material turnover rate ranges from 30 to 50%. Like other powder technologies, Fuse 1 is characterized by the fact that it does not require support structures to create cantilevered parts, meaning lower waste and an easier post-processing situation as there is no support removal needed. Furthermore, the high print density enables a high-efficiency print with low waste.

To ensure a correct manufacturing process, the machine integrates a pressure-controlled two-stage filtering system with replaceable HEPA and carbon filters. If we focus on other technical features of the 3D printer, we highlight the connectivity (Wifi, USB, Ethernet) and the integrated control touch screen. In addition to the machine itself, Formlabs has also developed a post-treatment station called Fuse Sift to carry out the removal of the remaining powder from the parts.