This printer should be your go-to printer if you are a small business owner whose customers are getting rid of the quality that FDM and SLA printers provide. The store will not work correctly in the case when cookies are disabled. Its part packing algorithms can automatically arrange multiple models in a build, enabling more effective prints. There has to be a better way to print nylon, then. With the Fuse1, you can also print with up to 50 per cent recycled powder. Similarly, the printer did an excellent job with the planetary gear system. The Fuse 1 is priced at $18,499, while the complete setup starts at $31,845. To aid with the powder removal step, users will find it handy to make use of the vacuum cleaner included in the box. Backed by over seven years of research and development, the Fuse 1 was marketed as the worlds first industrial-grade benchtop SLS machine, combining high-performance with a compact footprint. The use of the roller allows for improved powder packing and a more uniform powder distribution, which is crucial for achieving high part qualities. And at the other end of the scale, you can print beautifully-detailed models. To support the new printer and provide users with an end-to-end SLS workflow, the company also launched the Fuse Sift, a post-processing system for the Fuse 1, and Nylon 12 Powder. In terms of energy source, the Fuse 1 features one ytterbium fiber 10W laser diode with a wavelength of 1065nm, a beam divergence of 4.01mrad, and a spot size of 200 microns. With the Fuse 1, you can 3D print high-performance machine parts, tools, living hinges, jigs, jaws, and fixtures. The Fuse 1 takes about an hour to heat its build chamber up before actually firing up the laser, although this pre-print heating process is automatic. There's no need for support structure on any model design, and you can print consolidated models in one sitting. This year, their latest 3D printer, the Fuse 1, will go on sale. Firstly, its important to carefully consider the location of both the Fuse 1 and Fuse Sift in the workshop. Receive the latest manufacturing news and technical information by subscribing to our monthly and quarterly magazines, weekly and monthly eNewsletters, and podcast channel. Finally, if you run into a problem you cant solve yourself, you can always contact Formlabs directly and theyll be able to look at the log file of your machine to analyze the issue. The Fuse 1 has a build volume of165mm x 165mm x 300mm and, combined with the Formlabs Fuse Sift, canproduce fully-functional parts at an industry leading 30% powder refresh rate with unlimited cycles. Once a build is complete, youll also need to let it cool down before transferring the build chamber over to the Fuse Sift. Tons of different industries are showing interest in the Fuse 1. You can make do by making your print in pieces, and then assembling, however, sometimes you'll just need a larger build area. Photo by 3D Printing Industry. Again, we were very impressed with the performance of the Fuse 1 here as it demonstrated just how effective it was at producing highly-detailed display models. Fuse 1s hopper can hold 18.7 lbs (8.5 kg) of Nylon 12 and offers a material refresh rate of 30-50 percentmeaning up to 70 percent of the powder can be recycled, indefinitely according to Formlabs. Here, users can fill the Fuse Sift with fresh Nylon powder to be recycled with the used powder previously reclaimed at the sieving station. 3D Printing Industry reviews the Formlabs Fuse 1 3D printer and Fuse Sift post-processing system. The sieve comprises a wide grid of small holes that allow unused powder to pass through, while catching larger lumps of powder that have been heated and fused together. Overall, the Fuse 1 has given our clients the freedom and ability to save big on setup costs, fulfillment time, and unsold back stock. Connectivity options include USB, Wi-Fi, and ethernet, so feel free to take your pick. Beyond just a robust set of hardware components, the system offers a highly refined user interface, a digestible learning curve, and one of the best repeatability profiles weve ever tested here at 3D Printing Industry. For the best experience on our site, be sure to turn on Javascript in your browser. Now, Formlabs, known for its Form line of desktop stereolithography (SLA) printers, is looking to play a bigger role as it today announced the availability of its Fuse 1 benchtop industrial selective laser sintering (SLS) 3D printer. It's also extremely strong. The Fuse 1 scaling down SLS 3D printing. Compared to other SLS 3D printers, the system is highly space-efficient, measuring just 645 x 685 x 1070mm (1655mm tall with the stand). Whether that's to create jigs, jaws and fixtures, or casings for consumer electronics, there's always something. Special thanks to Solid Print3Dfor allowing us to visit their facilities and perform the testing required for this review. We kick things off with a circular trajectory test, which is designed to determine the repeatability of the 3D printer in both the X and Y axes. Formlabs has equipped the Fuse 1 with a 165 x 165 x 300mm build volume, meaning users have 8.17L of workspace to play around with. In this case, both objects feature internal cavities and a plethora of holes that allow us to judge how the Fuse 1 prints complex geometries without any support structures. The printer itself measures 677 x 668 x 1,059 mm, which is relatively compact even compared to desktop FFF 3D printers, and weighs 88kg. Surface Armor was developed after Formlabs noticed that parts printed with low energy-density showed no evidence of a rough surface texture. The PreForm slicer is fast, bug-free, and responsive, just how we like it. Of all the plastic additive manufacturing technologies, it provides users with the highest resolution and accuracy, as well as the smoothest surface finish. It's also important to point out that the Form 2, Formlabs' SLA 3D printer, does not support nylon. The slicer offers one-click printing, an intelligent feature that automatically nests the chosen 3D models in the build area to minimize both powder usage and print time. Looking at the control system, the firm has implemented its own set of custom galvanometers operating on a polar coordinate system. SLS 3D printers use a high-powered laser to selectively 'sinter' material. Due to the fineness of the powder particles, its also recommended to wear adequate PPE at all times when exposed to airborne powder. In the end, the Fuse 1 and Sift are a formidable duo and any criticisms are dwarfed by the sheer value offered by these systems. For example, neither of the systems should be placed next to a sandblasting machine as the sand could very easily taint the Nylon in the powder bed. Company no. We partner with a wide range of manufacturers with over 30 different printers between them, capable of printing in a variety materials from PLA to metal. Featuring patent pending Surface Armor technology, the Fuse 1 creates a semi-sintered shell that prints around the surface of the part, protecting the part during the print process and enabling great surface finish, high reliability, and high refresh rates, according to the company. Much to our delight, the system held its own admirably here, with both parts printed without any defects. Featured image shows the Fuse 1 3D printer. SLS 3D printing shouldnt be solely for those with big budgets, it needs to be accessible so all companiesfrom startup to big manufacturercan benefit from the design freedom and high productivity SLS 3D printing provides.. A better technology. Despite this office-friendly image, the Fuse 1 is being used for end part production and in larger manufacturing farms. It was designed, printed, and painted by Solid Print3Ds Benjamin Keyser. This has proven to be a highly useful workflow overview tool. Elongation at break is rated at 11 percent on the X/Y axis and six percent on the Z axis. The Fuse 1 is a desktop 3D printer that prints high-resolution prototypes, jewelry, and art with innovative engineering and a beautiful design. The company discovered that if they treated the printed parts edges with very low energy input, they could keep the bulk of the part printed at full energy density and maintain its mechanical properties all while using low energy density on the edges to prevent birchbark from forming. From 3D-printed figurines for students to quantum dots and nanocomposites, Olga Ivanova is a force to be reckoned with in the AM universe. Nylon 12 has a 50-52 MPa ultimate tensile strength rating, with 12 cent elongation at break. 3615 Superior Avenue
The Fuse Sift stress-free post-processing. SLS has long been trusted for its ability to print strong, functional parts, however its high cost and complex workflow have limited the size of companies able to benefit from it. The parameters that Formlabs has chosen work exceptionally well and result in high-quality prints every time, although it does mean that the system is only compatible with the companys own Nylon powders. According to Formlabs, their Nylon 12 powder offers an ultimate tensile strength of 50 MPa with a tensile modulus of 1,850 MPa. Sources: SLS Guide (Formlabs), Fuse 1 (Formlabs). Ensuring that you choose the right additive manufacturing solution for your application is our priority and we know that one size rarely fits all. Nylon 12 offers flexural strength of 66 MPa and a flexural modulus of 1,600 MPa, according to the company. The streamlined printing workflow coupled with the reliable and refined processing parameters of the PreForm slicer make the Fuse 1 an ideal system for short-run functional applications. The V6 engine block and exhaust manifold are typically the kinds of parts a carmaker would prototype in the design phase of a new model. However, just as machining is not the best fit for all forms of traditional metal manufacturing, SLA has its areas where it shines and its own set of limits. The nearest thing to nylon it prints is Tough Resin. The workspace, which is guarded by a transparent acrylic shield, is well thought out with all of the individual stations arranged neatly in order. Whats most impressive is that the Fuse 1 managed to print each and every one of the tiny components without accidentally fusing any of them together, despite the extremely tight spacing in the joints and gaps. Finally, on the right side of the workspace is the fresh powder tank. It is, however, a niche product that's engineered for industrial applications. As it stands, the system is able to 3D print two different polymer materials (Nylon 11 and Nylon 12) and Formlabs is working hard to expand the range of compatible powders. The Fuse 1 is an impressive 3D printer, both in isolation and on the spec sheet. But, the Fused Filament Fabrication 3D printers that can print it offer limited performance. In the best case, 99.6% of the 100mm circles manufactured by this 3D printer will be between 99.93mm and 100.07mm. Based in Somerville, Massachusetts, Formlabs is undoubtedly one of the biggest names in professional-grade SLA 3D printing. The tank is fitted with a rubber seal to stop any used powder from accidentally mixing in with the fresh powder prematurely. Kubi Sertoglu holds a degree in Mechanical Engineering, combining an affinity for writing with a technical background to deliver the latest news and reviews in additive manufacturing. The company states its Nylon 12 provides high tensile strength, ductility, and environmental stability, making it suitable for creating complex assemblies and durable parts with minimal water absorption. Please note the Technical Specifications are provided by the Manufacturer and may be subject to change. Formlabs Fuse 1 High Efficiency Package: Recommended set up for efficient SLS workflow, Formlabs Fuse 1 Workflow Essentials Package: Everything required for SLS set up. It has a 165 x 165 x 320 mm build volume, will print at a speed of up to 10 mm / hour, and boasts a 110 m layer resolution (110-microns). On the software performance side, theres not much to complain about at all. Under development for nearly seven years, the Fuse 1 marks a notable change for Formlabs as they expand into a new additive manufacturing process. Additionally, the build chamber is modular in that it can be removed in its entirety. You are free to manage these via your browser settings at any time. For context, industrial 3D printing systems often boast dimensional accuracies of up to 0.1mm, which qualifies them for high-precision manufacturing in critical industries such as automotive and aerospace. The powders used in SLS are extremely fine and prone to contamination, so its crucial that the work area is free from potential contaminants such as dust or waste from other machines. Coupled with the Fuse 1, the post-processing station makes powder removal and recycling as streamlined as can be, resulting in a well-designed, entirely end-to-end SLS 3D printing workflow. The machine features a full metal chassis with one door at the front providing access to the build area.
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