Formlabs Fuse X1
Hardware Overview
● Build Big: Produce full-scale production-quality parts in a massive build volume or run production builds at over 30% packing density to manufacture thousands of end-use parts in days, not weeks.
○ 330 × 330 × 565 mm build volume.
● Low Part Cost: Fuse X1 delivers up to 50% lower part cost than legacy powder bed fusion systems in less than half the floorspace. Fuse X1 is cost-competitive with injection molding for tens of thousands of parts.
● Productive: With 30%+ packing density and a 61.5L build volume, the Fuse X1 fits more parts in a single build than competing industrial SLS and MJF systems, adding up to thousands more parts per week.
○ 3x throughput vs. Industrial Competitors
● Intuitive and Reliable: Fuse X1 fits through a standard door, doesn’t require facility retrofit, and installs and prints on day one. An intuitive touchscreen guides you, while the build unit enables 5-minute changeovers.
Technology
● Adaptive Thermal Control enables unlimited packing freedom and exceptional part quality by delivering, maintaining, and sintering powder at an incredibly stable temperature.
● Print Intelligence uses AI-powered computer vision to isolate and prevent failures, maximizing uptime so you get great parts on time every time.
Fuse X1 Build Unit
The Fuse X1 build unit contains and transports prints throughout the Fuse X1 ecosystem. It is wheeled and mobile to easily move between the Fuse X1 during printing and Fuse Sift X1 for breakout, with blind-mate power and data connectors for ergonomic print changeovers. An insulated chamber allows the print to passively cool outside of the printer, enabling the next print to start with minimal downtime.
Fuse X1 Vacuum Conveyer
Fuse X1 Vacuum Conveyor is the building block of the powder transport system. One unit on the Fuse X1 loads refreshed powder into the printer, and a second unit moves sifted reclaimed powder from the Fuse Sift X1 to the Mix Kit or mixing setup of your choice. Additional vacuum conveyors can be used to transport and manage powder as desired to minimize bottlenecks, such as storing powder in large format containers. Each Vacuum Conveyor ships with mounting hardware and a vacuum hose. One Vacuum Conveyor is included with the Fuse X1 and one with the Fuse Sift X1.
Fuse X1 Mix Kit
Fuse X1 Mix Kit simplifies powder management by automatically blending reclaimed powder from the Fuse Sift X1 with fresh supply at the precise refresh rate. An included scale ensures an accurate mixing ratio for every batch. Once mixed, the Fuse X1 Vacuum Conveyor loads the material into the printer for the next job. For high-volume operations, additional Vacuum Conveyors can be added for additional flexibility to transfer and store powder as desired.
Workflow
Large Format SLS, Simplified
An end-to-end industrial workflow you can install and run in one hour. No dedicated operator required.
PREPARE
Auto-pack, optimize, and organize in PreForm: Orient, hollow, or label models, estimate print times, and automatically pack parts for optimized density, reducing print time and limiting waste. Import STL, OBJ, 3MF, or models directly from a wide range of CAD applications.
Print large parts in hours, not days: Most large builds complete under 24 hours, with same-day large parts in 5 hours. Print Intelligence detects and masks anomalies in real time to protect yield.
SWAP
5-minute print changeovers with the Fuse X1 Build Unit: Roll one build unit out, roll the next one in, with blind-mate power and data connectors. Insulation allows natural cooling inside the unit, so the printer can start the next job
UNPACK
Hands-off powder recovery with Fuse Sift X1: Integrated compressed air, sealed glovebox, and parts hatch keep breakout clean and fast. Capacity for 3 to 5 full builds of used powder, with automatic powder transport to the Mix Kit.
FINISH
Clean and Polish with Fuse Blast: New 400 mm Fuse Blast Large Tumbler Basket fits 2-3× Fuse build volumes and 50% more parts per cycle. Optional Polishing System upgrade delivers smooth, semi-gloss, dye-ready surfaces.