Today, Formlabs announced the release of a new large-format SLS ecosystem that delivers same-day production-quality parts at 50% lower cost and 3x the throughput of competing systems. The ecosystems are being sold starting at $84,999, and are currently available for order with deliveries starting Q4 2026. This selective laser sintering system is designed to make high-throughput additive manufacturing more accessible to manufacturers, engineering teams, product developers, and service bureaus.
In addition to announcing the machine release, Formlabs shared that early access customers across automotive and consumer products, including Tesla, Radio Flyer, and Autotiv Manufacturing, have already used Fuse X1 to accelerate product development and scale production to print more than 30,000 parts in just four months. The system is meant to offer reliable and scalable decentralized manufacturing, while being more affordable than comparable options.
“Since the beginning, Formlabs has worked to build the tools that make it possible for anyone to bring their ideas to life,” Max Lobovsky, co-founder and CEO of Formlabs said. “With Fuse X1, we’re bringing industrial-scale SLS printing to a much broader market, making it competitive with traditional mass manufacturing. Customers no longer need to spend half a million dollars or dedicate an entire facility to manufacturing production-grade parts quickly and reliably.”
It’s a large-format printer, but the Fuse X1 ecosystem fits through a standard door, installs in about one hour, and operates on standard single-phase power without specialized HVAC requirements. The Fuse X1 ecosystem includes the Fuse X1 printer and modular Build Unit, Fuse Sift X1 for powder recovery, Fuse X1 Vacuum Conveyor for automated powder transport, and a new high-capacity configuration for Fuse Blast for media blasting and polishing. Key specifications and capabilities include:
- 330 × 330 × 565 mm build volume, with 30%+ packing density
- 50% lower part cost versus legacy industrial SLS and MJF printers
- Less than half the floor space versus legacy industrial SLS and MJF printers
- Same day large parts and 3x the throughput of competitors
What’s New about the Fuse X1: Adaptive Thermal Control, AI-Powered Print Intelligence
The Fuse X1 is also coming with two new features: Adaptive Thermal Control and AI-Powered Print Intelligence. Adaptive Thermal Control allows for unlimited packing freedom in large-format SLS for the first time, with a new thermal architecture designed to maintain stable print conditions across the build chamber. According to Formlabs, it collects and processes 700 times more thermal data per second than the Fuse 1+ 30W, driving 13 independent thermal zones that deliver, maintain, and sinter powder at a precise and stable temperature throughout the entire print process. The maximum recommended packing density for MJF 3D printers is approximately 10-15%. Meanwhile, the Fuse X1 can achieve over 30% volume packing density to fit more parts per build, achieving unprecedented throughput.
Print Intelligence is an AI-powered failure prevention system that uses computer vision to monitor every layer with thermal imaging to detect anomalies before the build fails. The system detects part defects in real time and selectively removes the affected part from the following layers. This saves users materials and time.
Which Companies Have Already Used The Fuse X1?
Formlabs shared that early access customers have already used Fuse X1 to accelerate product development and scale production. Tesla adopted the Fuse X1 to speed up product development and to produce end-use parts and tooling for its manufacturing line, benefiting from the printer’s build volume and throughput. “With the increased throughput and decreased costs, Fuse X1 has completely changed our perspective on what kinds of projects our lab can support versus what we would have traditionally moved to an injection mold.” Cody Jepson, Engineering Technician, Additive Manufacturing at Tesla Giga NV.
Radio Flyer, the American toy and electric bike brand, reduced prototype lead times for its Flyer Loop cargo ebike frame. “With Fuse X1, we can now print an entire Flyer Loop cargo ebike overnight and be gluing it together the next day. So we went from two months to two weeks to a couple of days. I can iterate three times as often with nine times less labor,” said Agostino LoBello, Product Development Engineer at Radio Flyer.
Fuse X1 parts will also be available for order for customers in the US starting today on Formlabs’ new online 3D printing service, Form Now. Fuse X1 will be first showcased in public at the Reindustrialize Summit on June 16th in Detroit, MI.
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*Cover Photo Credits: Formlabs