61.5 L Industrial Build Capacity
With a build volume of 330 × 330 × 565 mm, approximately 7.5 times that of the Fuse 1+ 30W, the Fuse X1 can accommodate large prototypes, high-mix part portfolios, or large quantities of small end-use parts.
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Large, High-Speed, and Scalable Industrial-Grade Powder Sintering System
Formlabs Fuse X1 Industrial SLS 3D Printer
From full-size functional prototypes and high-mix low-volume manufacturing to mass production of thousands of end-use parts, the Fuse X1 integrates large build volume, intelligent process control, and automated powder workflow into a single SLS production system.
The Fuse X1 offers a build volume of 330 × 330 × 565 mm, with a total capacity of 61.5 L, increasing part throughput within a limited equipment footprint and shortening time from design to finished product delivery.
330 × 330 × 565 mm Build Volume
120 W Fiber Laser Print Engine
AI-Powered Print Failure Prevention
Deliver full-size parts overnight, or rapidly produce mass-market goods with the latest designs.
Large Build Space Supports Various Production Scenarios
Batch Production
Completed in approximately 41.5 hours, with a build density of about 41%, suitable for large quantities of small end-use parts and repetitive production.
High-Mix Builds
Completed in approximately 22.5 hours, with a build density of about 10%, suitable for multi-item prototyping, spare parts, and low-volume customized manufacturing.
Full-Size Prototypes
Completed in approximately 21 hours, with a build density of about 2%, suitable for large enclosures, automotive components, and full-size functional validation.
Scale production and reduce management costs, lowering per-part cost by up to 50%.
Reduce Part Costs and Shorten Delivery Times
The following cases compare estimated per-part costs and delivery times for Fuse X1, outsourced manufacturing, and older SLS equipment. Actual results may vary depending on material, build configuration, labor, and regional costs.
20 Drone Frames
| Fuse X1 | $59 / 2 days |
|---|---|
| Outsourced Manufacturing | $239 / 14 days |
| Older SLS Equipment | $115 / 5 days |
1 Car Door
| Fuse X1 | $792 / 3 days |
|---|---|
| Outsourced Manufacturing | $1,853 / 14 days |
| Older SLS Equipment | $1,307 / 5 days |
3,280 Mixer Locks
| Fuse X1 | $0.50/piece / 5 days |
|---|---|
| Outsourced Manufacturing | $22/piece / 14 days |
| Older SLS Equipment | $1.56/piece / 7 days |
1 Electric Bicycle Frame
| Fuse X1 | $990 / 3 days |
|---|---|
| Outsourced Manufacturing | $3,623 / 14 days |
| Older SLS Equipment | $3,010 / 5 days |
Provides up to 3 times the throughput in less than half the footprint of some traditional industrial systems.
High-Density Builds with a Compact Footprint
More Parts in a Single Build
The Fuse X1 offers a 61.5 L build volume, with fill densities over 30% higher than some competing systems, allowing more parts per single build and increasing overall weekly production.
Suitable for Existing Production Spaces
With a footprint of approximately 1.3 m² and the ability to fit through standard doorways, the Fuse X1 facilitates the integration of production-grade SLS equipment without significant factory layout changes.
Print Intelligence Smart Print Failure Prevention
The Fuse X1 combines computer vision, adaptive thermal control, and real-time process monitoring to identify print anomalies and adjust affected areas, minimizing the impact of a single anomaly on an entire batch of parts.
How Smart Printing Works
The system can detect anomalies in real-time and isolate affected areas, helping to reduce the risk of entire build failures and increase yield while maintaining the quality of other parts.
Adaptive Thermal Control
The thermal imaging system captures and processes large amounts of process data per second, driving 13 independent heating zones to precisely control powder heating and sintering status from the first layer to the last.
120 W Fiber Laser Print Engine
A 120 W fiber laser with high-speed customized galvo quickly and precisely scans the entire build area, producing high-density, high-precision parts.
Modular Print Unit
The print unit can be quickly loaded or unloaded, allowing the next job to be prepared while the previous build is still cooling, reducing downtime between print jobs.
Integrated Powder Delivery System
The vacuum conveying system automatically transfers powder between printing, reclaiming, and refilling stages, reducing bin handling, manual scooping, and powder exposure.
Dynamic Powder Dosing Control
Stable powder distribution and a rapid layer-by-layer spreading process reduce waiting time between layers and minimize material waste caused by overflow powder.
Industrial workflow is also quick to get started: shorten installation time and be ready to print in minutes.
Complete Workflow from Preparation, Printing to Powder Recovery
Prepare Print Job
Configure parts in PreForm and integrate different builds, materials, and printer jobs into a single project document.
Start Printing
Quickly connect the print module and prepare materials via the automatic powder loading system, reducing cleaning and manual setup between print jobs.
Remove Build and De-powder
Transfer the build chamber into the Sift X1, and complete part removal and initial powder cleaning in a closed environment using the integrated glovebox and compressed air.
Clean and Polish
Fuse Blast provides automatic cleaning and polishing functions, capable of processing large parts and entire builds, improving consistency and efficiency of post-processing.
Refresh and Refill Powder
Use the vacuum conveying system to mix reclaimed powder with new powder, completing material replenishment and loading for the next print.
Rapidly reclaim powder at scale, maintaining continuous production and a clean working environment.
High-Capacity Powder Handling
Can hold reclaimed powder from approximately 3 to 5 builds, maintaining processing capacity while reducing workspace occupation.
Part Transfer Bay
Parts removed are centrally transferred into a transfer box, quickly freeing up the main work area for subsequent processing of the next batch.
Sealed Work Area
The integrated glovebox keeps de-powdering operations within a closed environment, helping to improve powder management and workspace cleanliness.
Waste Powder Recovery
Rapidly collect and process waste powder, reducing the time traditionally spent on manual brushing and repetitive cleaning of parts.
Achieve ready-for-use SLS parts in less time through automated cleaning and polishing.
Fuse Blast Automated Cleaning and Surface Finishing
Clean and Dyeable Part Surfaces
Built-in ion generator reduces dust and media re-adherence, and with the polishing process, achieves smoother, semi-gloss surfaces suitable for subsequent dyeing.
Automated Cleaning Process
Preset automated programs can process parts of an entire print volume in about 10 minutes, reducing continuous manual operation and parameter setting.
Save Time and Consumable Costs
The waste separation system reduces the saturation speed of cleaning media, extending media lifespan and shortening cleaning time after parts are removed from the powder bed.
Multi-functional Manual Mode
Switch between automatic, manual-assisted, or handheld modes according to part size and geometry to handle detailed areas and complex structures.
High-Capacity Processing Kit
The Fuse Blast high-capacity kit can be directly installed to process more parts per cycle, increasing throughput for large-volume post-processing without equipment modification.
High-performance end-use thermoplastic materials, combined with powder recovery workflow, reduce per-part production costs.
Industrial-Grade SLS Powder Materials
Nylon 12
Combines dimensional accuracy, fine detail, and general mechanical properties, suitable for functional prototypes, jigs, fixtures, enclosures, and end-use parts.
Nylon 11
Features high ductility and impact resistance, suitable for snap-fits, thin-walled structures, sporting goods, and parts requiring repeated deformation.
TPU 90A
Flexible and elastic thermoplastic polyurethane material, suitable for cushions, grips, seals, footwear prototypes, and flexible end-use parts.
Nylon 12 GF Glass-Filled Nylon
Glass fiber reinforced material offers high rigidity, dimensional stability, and heat resistance, suitable for jigs, fixtures, and demanding industrial applications.
Open Materials Mode
With customizable print settings, research and materials development teams can explore other powder materials and new applications suitable for 1064 nm laser systems.
| Comparison Item | Fuse X1 | Fuse 1+ |
|---|---|---|
| Positioning Type | High-Performance Industrial 3D Printer | High-Performance Desktop SLS 3D Printer |
| Laser Type | 120W Fiber Laser | 30W Fiber Laser |
| Print Volume | 330 × 330 × 565 mm (61.5 Liters) | 165 × 165 × 300 mm (8.2 Liters) |
| Throughput (Capacity) | 0.330 kg/h | 0.063 kg/h |
| Footprint | 12.2 sq ft | 4.8 sq ft |
| Print Environment | Nitrogen | Air and Nitrogen |
| Supported Materials | Nylon 12, Nylon 11*, Nylon 12 GF**, TPU 90A Powder**, or any 1064 nm powder with Open Materials Mode. | Nylon 12, Nylon 12 Tough, Nylon 12 White, Nylon 11, Nylon 12 GF, Nylon 11 CF, and TPU 90A Powder, or any 1064 nm powder with Open Materials Mode. |