Since entering the 3D printer market in 2012, Formlabs has quickly gone from an MIT-startup spinoff to an industry leader. Known for its stereolithography (SLA) printers, the company has taken things to a new level with the release of its Fuse 1, which has been in development for seven years.
This industrial selective laser sintering (SLS) 3D printer expands the company’s offerings into new additive manufacturing (AM) processes. SLS has been a staple in the 3D printing sector due to its ability to reliably produce durable and functional parts. Its downsides have been its associated costs and workflow complexity. The new Fuse 1 aims to change that.
“SLS 3D printing shouldn’t be solely for those with big budgets, it needs to be accessible so all companies—from startup to big manufacturer—can benefit from the design freedom and high productivity SLS 3D printing provides,” said Max Lobovsky, Formlabs CEO and cofounder.
Along with developing a new printer that was cost-effective—Fuse 1 starts at $18,499 compared to others starting at $200,000—the company wanted to incorporate an end-to-end workflow, giving clients more control over the process. Formlabs also released Fuse Sift, which is a post-processing system for the new printer. The extra system raises the base price for Fuse 1 to $31,845.
Fuse 1, which measures at 25.4 x 27 x 42 ft, allows for a 6.5 x 6.5 x 11.8 inches build volume and can create a thickness of .0004 in. A second removable chamber makes it possible to start printing again after an approximate one- to two-hour cooldown. The printer also uses a new material, Nylon 12, which has a tensile strength of 50 MPa. According to the company, its high tensile strength, environmental stability and ductility is ideal for complex assemblies and minimizes water absorption.
When used with the Fuse Sift, which measures at 39 x 24 x 61.8 ft, users have the ability to create a cyclical, nonstop workflow. Fuse Sift combines post-processing elements into one unit, including powder recovery station, part extraction and storage. The system automatically dispenses and mixes new powder, which equates to waste reduction and enhanced management of the powder supply. It uses a negative air pressure system to keep the powder in its place while also ensuring easy cleanup and access.
The Fuse 1 features a newly developed, patent pending Surface Armor technology, which came about as a solution to prevent low energy density prints from having unwanted textures forming. According to Formlabs, the technology enables the Fuse 1 to print a protective semi-sintered shell around the surface of the part during printing, which enables great surface finish, high reliability and high refresh rates.
Other highlights of the Fuse 1 include the ability to monitor print processes, import STL or OBJ files, upload job files, and orient and arrange models. Algorithms have been developed for part packing, allowing for automatic arrangement of multiple models. When it comes to monitoring, users can view a live stream of the process via a touchscreen display with a camera view, even if they are away from the printer.
Interested in more 3D printing news? Check out Xolography—The Latest Innovation in 3D Printing and HP Reveals Multi Jet Fusion 3D Printer and New Era of Manufacturing.