A new level in SLS 3D printing: The Formlabs Fuse 1+ 30W SLS 3D printer

The compact SLS 3D printer for high throughput and high-performance materials

The delivery of the Formlabs Fuse 1 Selective Laser Sintering (SLS) printer has dramatically changed the printing landscape. Formlabs has sold more SLS printers than any other manufacturer since 2020. Now, two years later, Formlabs is responding to feedback from thousands of users and introducing the Formlabs Fuse 1+ 30W SLS printer. Among other things, it offers up to twice the printing speed of its predecessor.

The Formlabs Fuse 1+ 30W includes a number of enhancements and improvements. These include a new, more powerful 30 watt laser with a higher scanning speed, improved powder handling and the option of printing with nitrogen purging. With the Formlabs Fuse 1+ 30W, users can increase throughput and have the option of using new high-performance materials.

Components in hours instead of days

Regardless of whether a single prototype needs to be produced or the machine is running continuously for final production, speed is of key importance for many industries. To reduce the overall printing time, the core of the printer was therefore upgraded first: The Formlabs Fuse 1+ 30W has, as the name suggests, a new, more powerful 30 watt laser as well as improved laser scanning. Thanks to these two innovations, the Formlabs Fuse 1+ 30W achieves a very high printing speed. This is up to 2x faster than that of the Formlabs Fuse 1.

In addition, the distance between the components has been reduced for the Fuse 1+ 30W. This allowed the packing algorithm to be optimized. It is now possible to print more components or several versions of a component within 24 hours. This means that they can be tested or used the very next day.

Many products today are highly specialized. As a result, designers or entire design teams often work exclusively on individual small components. If there are no other parts or projects to work on, they have to wait idly until the designs are printed or delivered by a manufacturing service provider before they can move forward with the iterative process.

Due to the higher printing speeds of the Formlabs Fuse 1+ 30W, this “waiting time” can be postponed until the night. This makes the design process much more efficient. You can carry out more iterations and have more time for functional tests. This means you get more feedback, which leads to better products and a faster ROI.

An example of the printing speed: bicycle saddle

Highest possible throughput

With the current shortage of raw materials, rising order costs and plant closures, manufacturers are looking for ways to regain control of their supply chains. With the latest material innovations, 3D printing of end-use parts is not only possible, but the best choice for validation phases and customization or individualization and small batches.

The Formlabs Fuse 1+ 30W allows even SMEs to use SLS 3D printing in-house. As a result, they achieve greater independence from suppliers, as well as protection against delays and fluctuations in the supply chain. For large companies already using SLS 3D printing, the Fuse 1+ 30W offers the opportunity to decentralize 3D printing operations. This does not multiply the cost of their conventional SLS systems, but makes industrial-grade SLS 3D printing accessible to more engineers, designers and technicians with a much smaller investment. This broader access opens up new applications throughout the company, or SLS 3D printing is used to produce spare parts, fixtures, gauges, tools and much more.

An example of the printing speed: shaft coupling

Waste-free printing and better mechanical properties

3D printing for production purposes would not be possible without high-performance materials. To optimize powder usage, the Formlabs Fuse 1+ 30W comes with two new changes.

A new optional nitrogen supply creates an inert gas atmosphere during the printing process. This banishes unwanted oxygen from the sintering environment. Parts printed in this inert atmosphere are less brittle and more ductile. This makes them even more suitable for end applications, especially in demanding environments such as the automotive and aerospace industries. A wide range of compatible nitrogen generators are available. We will be happy to assist you in choosing a suitable model.

Nitrogen purging increases the efficiency of the sintering process with nylon 11 and nylon 11 CF powder, as unsintered powder is better protected against oxidation. As a result, less new powder needs to be added in the next printing cycle. This leads to a higher recyclability of the powder and, together with an optimum packing density, results in a waste-free printing process. Nylon 11 and Nylon 11 CF powders have a refeed rate of 50% without nitrogen purging. This means that 50% recycled and 50% fresh powder must be mixed for each new filling. The required proportion of fresh powder drops to 30% for both materials with nitrogen purging.

The waste-free printing process is not only more sustainable, but also means that every franc spent on materials is fully converted into the production of printed parts. Using the Formlabs Fuse 1+ 30W enables cost savings, sustainability and high-quality parts.

New feed rates depending on the printing environment

	NYLON 11 POWDER	NYLON 11 CF POWDER
Air	50 %	50 %
Inert gas	30 %	30 %

Active powder mixing enables new materials

The Fuse 1+ 30W features updated hardware that enables the use of new materials – such as Nylon 11 CF Powder, a carbon fiber-reinforced material for in-house production of stiff, strong and lightweight components.

The combination of carbon fibers embedded throughout the powder gives composites such as Nylon 11 CF Powder their increased strength and durability by reinforcing the material properties of nylon. Such materials require special powder handling that can maintain a uniform powder mix during the dispensing process.

The Formlabs Fuse 1+ 30W development team has developed a new agitator. This makes it possible to use such new materials. The new agitator is located in the powder hopper. There it ensures a constant, even supply of material into the build chamber. Thanks to this new development, nylon 11 CF powder can now be processed on the Fuse 1+ 30W. It also paves the way for other high-performance materials. Along with new materials, the improved powder handling opens up new fields of application in the aerospace, automotive, medical technology and consumer goods industries.

A system for low unit costs and a fast ROI

The Formlabs Fuse 1+ 30W is an affordable industrial-grade 3D printing solution in a small footprint. This gives SMEs not only the ability to perform SLS printing in-house, but also to scale their production. In addition to the affordable entry price, the low unit cost, faster turnaround time and streamlined workflow can also reduce overall production costs.

The low refeed rate reduces the amount of powder required and therefore the cost of the printer’s consumables. Together with the higher number of iterations and production cycles, this cost saving means that the printer pays for itself more quickly. Compared to the previous job costs, the purchase of a printer can pay for itself within a few months.

If you compare the costs for in-house production of SLS parts with outsourcing to an external contractor, the purchase of the printer pays for itself after an average of 3-4 months when used for prototype production, but after 6-7 months in production.

To do this, Formlabs sent files to the four leading service providers and requested SLS parts. They then averaged their prices and lead times. For in-house production, they used the Fuse 1+ 30W SLS 3D printer and Fuse Sift, charging $17/hour for labor.

Prototype: Automotive manifold

Material: Nylon 12 Powder
Quantity: 5 pieces

Production: Bicycle pedal

Material: Nylon 12 Powder
Quantity: 36 pieces

In-house 3D printing with the Fuse 1+ 30W printer delivered high quality parts with shorter lead times for both prototyping and production. This allows for a more intensive iteration process for prototypes or higher production throughput.

The Fuse 1+ 30W SLS printer builds on the success of the Fuse 1. It uses the same optimized workflow, high accuracy and compact format of the Fuse 1, but with improved print speed and powder handling, it also offers higher throughput capacities and more material options.