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.. The companys cloud-based Dashboard platform also enables users to track printers, teams, and supplies from anywhere. As such, the laser moves on the X and Y axes, whereas the bed moves on the Z-axis. 3615 Superior Avenue 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. Its part packing algorithms can automatically arrange multiple models in a build, enabling more effective prints. The Fuse 1 truly delivers on its promise of an accessible and cost-effective SLS experience, bridging industrial-grade print quality with a nifty, scaled-down footprint. Here, users can fill the Fuse Sift with fresh Nylon powder to be recycled with the used powder previously reclaimed at the sieving station. The machine features a full metal chassis with one door at the front providing access to the build area. 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. However, when you factor in the complex geometriesSelective Laser Sintering allows, the potential applications more than triple. Our measurement devices are accurate to 0.015mm. The use of the roller allows for improved powder packing and a more uniform powder distribution, which is crucial for achieving high part qualities. 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. The companys customer service is one of the best weve ever come across. Due to the intricacy of the model, we did have to disassemble it to remove all of the powder inside but once we ran the exploded assembly through a sandblaster, it turned out just at wed imagined it. The nylon powder is proprietary, so it's made by Formlabs to the highest possible specification. Similarly, the printer did an excellent job with the planetary gear system. To then refill the Fuse 1 3D printer, the user must fill an empty powder cartridge in the cartridge drawer of the Fuse Sift. So, if you want to 3D print with nylon, the Fuse 1 is for you. On the software performance side, theres not much to complain about at all. Of all the plastic additive manufacturing technologies, it provides users with the highest resolution and accuracy, as well as the smoothest surface finish. 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Special thanks to Solid Print3Dfor allowing us to visit their facilities and perform the testing required for this review. It's also heat resistant andhighly resistant to abrasion and chemicals such as acids and alkalis. Wed prefer it if Formlabs also allowed the user to access the log files themselves, but this is ultimately a minor gripe with what is an excellent after-sales service. Sources: SLS Guide (Formlabs), Fuse 1 (Formlabs). Nylon isabrasion resistant, heat resistant, and has a low friction coefficient. 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. So, in March of 2014, Formlabs asked itself if there was anything the company could do to make SLS, a process in which a high-powered laser fuses small particles of polymer powder into the final part, more accessible. 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. 08416238, This site uses cookies. 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. Once a build is complete, youll also need to let it cool down before transferring the build chamber over to the Fuse Sift. 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. It's also extremely strong. All in all, a very strong finish for the Fuse 1. 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. #mc_embed_signup{background:#fff; clear:left; font:14px Helvetica,Arial,sans-serif; width:100%;} /* Add your own Mailchimp form style overrides in your site stylesheet or in this style block. It is, however, a niche product that's engineered for industrial applications. There has to be a better way to print nylon, then. Its also relatively light, weighing in at 114kg without the build chamber or any powder. With such an awesome description, you'd think that the Fuse 1 could replace any old 3D printer you have lying around. Formlabs carefully crafted package is perfect for those seeking an accessible but comprehensive entry into SLS 3D printing. We previously used an outsourced injection-molding workflow to deliver prosthetic fingers to patients young and old, helping them improve mobility and increase functionality; but this process was extremely slow and did not allow for the personalization needed for each patient, said Matthew Mikosz, founder of Partial Hand Solutions and Fuse 1 beta user. To remedy this, the Fuse 1 also comes with a variety of smaller hand tools that can help address the more intricate part geometries, including brushes and needle-like spikes. 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. 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. An example being the bicycle seat in the image above, which was 3D printed with the Fuse 1 at 10 mm / hour with a 110 m layer resolution. 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. These are called DMLS 3D printers. Nylon, perhaps, is the most versatile of all materials. The standard cleaning process requires a quick wipe with ethanol. One of the main selling points of PreForm is that it only has one set of predefined process parameters that cant be modified. Then theres the Fuse Sift. 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. In terms of software and file compatibility, the Formlabs Fuse 1 will print .STL or .OBJ files and runs PreForm Desktop Software. Next up, we tasked the Fuse 1 with 3D printing three different prototype parts to see how the system would fare in a real-world automotive manufacturing environment: a miniature engine block, an exhaust manifold, and a decorative model of a car. The nearest thing to nylon it prints is Tough Resin. Selective Laser Sintering is one such option, and Formlabs thinks so too. With final parts that combine strength, flexibility, and detail, Fuse 1 prints are ready for rigorous functional testing, prototyping or end-use parts. Formlabs Fuse Sift, powder recovery system. Formlabs says the Fuse 1s cooldown times allow users to utilize a second removable build chamber and start printing 12 hours after the previous print has finished. The print preparation program is easy to use with a polished, clutter-free user interface. 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. Nylon 12 is the first powder material for the Fuse 1, but Formlabs noted Nylon 11 will be coming soon, while a flexible TPU and other materials are in development. Once the proper safety measures have been put in place, its important to appreciate that SLS is a hot process. To aid with the powder removal step, users will find it handy to make use of the vacuum cleaner included in the box. Having debuted its original Form 1 system almost a decade ago, the firm has since packed out an extensive portfolio of resin-based 3D printers such as the Form 3+, Form 3B+, Form 3L, and Form 3BL. The enclosed build chamber can be heated to 200C and even features a replaceable active carbon HEPA filter for safe indoor operation. The first is a PCB housing and the other is a custom structural component designed to join two tubes together. One of the most striking things about the Fuse 1 is its compact frame. From print setup to powder recovery, the easy-to-use hardware and software are designed to maximise efficiency at every step of the process. Weighing only 114 kg, this 3D printer is light enough to move around your workspace but big enough to print your largest designs. At a minimum, you should always have a mask when using Sift or a media blaster. Moving on, we put the Fuse 1 through its paces with two more static print tests, except this time the parts are designed for end-use applications. 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. Its now time for the benchmarking portion of the review, where we knuckle down and evaluate the raw printing performance of the Fuse 1 3D printer. 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. Selective laser sintering uses a laser to precisely fuse nylon powder into lightweight, robust parts. 3D Printing Industry reviews the Formlabs Fuse 1 3D printer and Fuse Sift post-processing system. On the other hand, the model car is a 1954 MG TF. Receive the latest manufacturing news and technical information by subscribing to our monthly and quarterly magazines, weekly and monthly eNewsletters, and podcast channel. Formlabs includes a set of finishing tools with the Fuse Sift to help users clean excess powder from parts with ease, including a large brush, two small brushes, pipe cleaners, dental picks, a vacuum brush tool and a vacuum crevice tool. Complete set up of Fuse 1 system starts from 24,383.00 -view packagesor contact us to build your own package, The Fuse 1 is a Class 1 Laser product. SLS allows designers to create complex interior components using unique geometries, and it allows engineers to reproduce parts with precise replication. You'll get a 165 mm x 165 mm x 300 mm in the formlabs Fuse 1, so make sure everything you want to print fits in this. Formlabs bills its Fuse Sift as an all-in-one powder recovery station, combining part extraction, powder recovery, storage, and mixing in a single device. The laser traces a pattern in the nylon powder, one layer at a time, to form a solid model. 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. Formlabs improves on SLS with the Fuse 1 and Fuse Sift, bringing it within reach for all companies through affordability and ease of use. 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. The Formlabs Fuse 1 SLS 3D printer comes with: Please note, this price is for the Fuse 1 printer only. The tank is fitted with a rubber seal to stop any used powder from accidentally mixing in with the fresh powder prematurely. The success of the puzzle cube is a testament to the precision of the systems laser and galvanometers. Connectivity options include USB, Wi-Fi, and ethernet, so feel free to take your pick. While many industries have been on hold during COVID-19 pandemic, additive manufacturing has been getting red hotproving its value as it helped provide critical personal protective equipment (PPE) and allowed strained supply chains to flex without breaking. Buy the Fuse 1 and Fuse Sift here. Elongation at break is rated at 11 percent on the X/Y axis and six percent on the Z axis. So, this is a heavy 3D printer, but rest assured that translates to rock solid performance. Having a physical sample of a 3D printed part in your hand to show quality, material properties, durability and abilities can ultimately help the decision-making process. The Ytterbium Fiber 10W laser provides a laser spot size (FWHM) of 200 m (0.0079") and is capable of producing a layer thickness of 110 m (0.004"). In other words, this isn't a gadget for an office user, but a serious piece of kit for engineers. SLS is not a new technology, but this is the first time it has been applied to a benchtop 3D printer with industrial-grade results. For more about how we use cookies, please see our, Formlabs Fuse 1 Workflow Essentials Package. Formlabs has very carefully designed the workflow of the post-processing system to be intuitive, making the lives of technicians everywhere as stress-free as possible. There's no need for support structure on any model design, and you can print consolidated models in one sitting. 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. For the best experience on our site, be sure to turn on Javascript in your browser. The parts proved ready to use straight out of the build chamber, with minimal post-processing required and excellent surface finishes all around. 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. In the best case, 99.6% of the 100mm circles manufactured by this 3D printer will be between 99.93mm and 100.07mm. A better technology. At just 39 x 24 x 61.8" (1.0 x 0.6 x 1.9 m), Fuse Sift will dispense and mix used and new powder automatically to reduce waste and control the users powder supply. This has proven to be a highly useful workflow overview tool. Markforged X7 Digital Forge Industrial Fleet Solution, Markforged X7 Digital Forge Industrial Quality Solution. You can print housings, casings, shells, and electronic components. Formlabs PreForm print preparation allows users to import STL or OBJ part files, orient and arrange models, estimate print times, monitor printers, and upload job files. The Fuse 1 is a SLS printer, which can make highly detailed and complex models with nylon using a process that has not been accessible to prosumers. Sean gets an in-depth look at the Fuse 1, several of its prints, and sends one of his own models through the SLS process to inspect its print quality! The Fuse 1 by Formlabs is a high performance, compact, affordable Selective Laser Sintering (SLS) platform. Boasting affordability compared to industrial SLS 3D printers, low maintenance and maximum uptime, the Fuse 1 ticks all the right boxes for designers and engineers. Most 3D printers that utilise this technology specialise in metal 3D printing. SLA, invented in the 1980s, was the first 3D printing process created and uses a laser to cure liquid resin into hardened plastic in a process called photopolymerization. The Fuse 1 prints with nylon powder exclusively. Additive manufacturing is thriving and continues to gain momentum with successes across diverse applications. The Fuse 1 displayed excellent repeatability here, with an average offset of 0.0331mm for the X-axis and 0.0285mm for the Y-axis, resulting in an average of 0.0308 mm for both axes. SLS 3D printers use a high-powered laser to selectively 'sinter' material. It is, in fact, the first Formlabs 3D printer designed from the ground up to print with nylon. Users will also find the stacking feature to be particularly useful especially on an SLS machine as it helps makes full use of the build volume. As far as limitations and shortcomings go, we thought the option to leverage third-party 3D printing powders wouldve been great. Wed also argue that the option to fiddle around with the slicing parameters or import custom printing profiles could lend itself to previously unseen innovation. We recommend moving this block and the preceding CSS link to the HEAD of your HTML file. This enables users to transfer the build chamber to the Sift post-processing station without even seeing the printed part, making powder removal and recycling a breeze. Well take a deeper dive into each of these stations and explain how they all work. Featured image shows the Fuse 1 3D printer. All Rights Reserved. The suspension system came out beautifully to say the least. The Fuse 1 is priced at $18,499, while the complete setup starts at $31,845. Overall, the Fuse 1 has given our clients the freedom and ability to save big on setup costs, fulfillment time, and unsold back stock. The only trade-offs versus an industrial-size SLS 3D printer are a slightly slower build time, and a smaller build volume. All in all, the Fuse Sift does everything it promises to and works like a charm. The PreForm slicer is fast, bug-free, and responsive, just how we like it. To complement the 3D printer, Formlabs also launched the Fuse Sift, a post-processing system for use with the Fuse 1. From 3D-printed figurines for students to quantum dots and nanocomposites, Olga Ivanova is a force to be reckoned with in the AM universe. It is the first 3D printer to offer industrial-grade SLS performance in a compact, benchtop-friendly package. Its worth noting here that each of the models was printed-in-place, meaning they were fabricated fully assembled despite technically comprising multiple individual components. The left side of the viewport is home to the basic translation, rotation, and rescaling functions that come as standard with all 3D printing slicers, while the right side displays the job info and list of models in the build. SLS has practical advantages over FFF or SLA for design and engineering applications. The Fuse 1 is an impressive 3D printer, both in isolation and on the spec sheet. Tons of different industries are showing interest in the Fuse 1. The Fuse Sift stress-free post-processing. It's also important to point out that the Form 2, Formlabs' SLA 3D printer, does not support nylon. According to Formlabs, their complete end-to-end SLS printing system takes the guesswork and challenges out of creating strong, functional parts while minimizing costs, freeing many organizations from their reliance on what the company claims are expensive and slow external solutions. 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. More on this later. The Fuse 1 truly delivers on its promise of an accessible and cost-effective SLS experience, bridging industrial-grade print quality with a nifty, scaled-down footprint. Subscribe to the 3D Printing Industry newsletter for the latest news in additive manufacturing. 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. Met-L-Flos eclectic business mix demands innovative AM solutions. Please note the Technical Specifications are provided by the Manufacturer and may be subject to change. Bouncing off its market-leading position in the SLA sector, Formlabs has made one hell of an SLS 3D printing debut. Printer maintenance is an unavoidable part of 3D printing. The Fuse Sifts sieve filters out particles to be remixed with new powder and reused in future prints. 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. Based in Somerville, Massachusetts, Formlabs is undoubtedly one of the biggest names in professional-grade SLA 3D printing. The Fuse 1's potential applications are largely dictated by its print material, nylon. 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. You can make do by making your print in pieces, and then assembling, however, sometimes you'll just need a larger build area. Most of the issues youll run into with the Fuse 1 can be attributed to two of the printers key components: the IR sensor and the optical cassette. As well as housing all of the printers core functionality, including printer calibration, file management, and build management, the touchscreen is used as a live video feed to monitor the inside of the build chamber while a part is being printed. A touchscreen display offers a live stream of the print bed and the camera view is also available from a computer through PreForm so users can monitor their print without leaving their desk. Unsurprisingly, the Fuse 1 delivered once again both the electronics casing and the joining component were printed virtually flawlessly. Fuse 1 gives us the design freedom needed to truly customize our prosthetics and the high productivity and throughput necessary to quickly get this solution to our patients.. This year, their latest 3D printer, the Fuse 1, will go on sale. Each of the gears was defect-free, sported clean surfaces, and meshed well with the rest of the assembly.
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