Fuse X1 Overview
The Formlabs Fuse X1 is a large-format industrial SLS 3D printer designed to make high-throughput production more accessible.
Built for manufacturers, service bureaus, and engineering teams, it combines a generous 330 × 330 × 565 mm build volume, AI-powered print monitoring, and an intuitive end-to-end workflow to help produce strong, accurate end-use parts at scale.
Formlabs positions its Fuse ecosystem as a scalable, accessible SLS platform for in-house production, with a workflow focused on reducing cost per part, labour, and time to market.
Formlabs Fuse X1 Features
Formlabs Fuse X1 Benefits
Simple, fast print set up
With Formlabs Preform print preparation software to import STL or OBJ part files, estimate print times, orient and arrange models, monitor your printers and upload job files.
PreForm's part packing algorithms can automatically arrange many models in a build to maximize the packing density, reduce print time, and limit waste.
Reliable Printing
SLS 3D Printing works by fusing nylon powder layer by layer.
You can create interconnecting, complex designs with no need for support structures as the unused powder supports the parts during printing.
The Fuse X1 offers competitive mechanical properties and surface finish without the prohibitive cost or hassle.
Adaptive Thermal Control & Print Intlligence
Adaptive Thermal Control enables unlimited packing freedom, and exceptional part quality by delivering, maintaining, and sintering powder at an incredibly stable temperature.
Print Intelligence uses AI-powered computer vision to isolate and prevent failures, maximizing uptime so you get great parts on time every time.
All-in-one powder recycling and recovery
The Fuse Sift X1, combines part extraction, powder recovery, storage, and mixing in a single device.
Produce fully-functional parts with competitively high powder recyclability to enable less waste and lower cost per part.
Fuse Sift will dispense and mix used and new powder automatically so you can reduce waste and control your powder supply.
Formlabs Fuse X1 SLS 3D Printing Process
1. Prepare
Auto-pack, optimize, and organize in PreForm: Orient, hollow, or label models, estimate print times, and automatically pack parts for optimized density, reducing print time and limiting waste. Import STL, OBJ, 3MF, or models directly from a wide range of CAD applications.
2. Print
Print large parts in hours, not days: Most large builds complete under 24 hours, with same-day large parts in 5 hours. Print Intelligence detects and masks anomalies in real time to protect yield.
3. Swap
5-minute print changeovers with the Fuse X1 Build Unit: Roll one build unit out, roll the next one in, with blind-mate power and data connectors. Insulation allows natural cooling inside the unit, so the printer can start the next job.
4. Unpack
Hands-off powder recovery with Fuse Sift X1: Integrated compressed air, sealed glovebox, and parts hatch keep breakout clean and fast. Capacity for 3 to 5 full builds of used powder, with automatic powder transport to the Mix Kit.
5. Clean
Clean with Fuse Blast: New 400 mm Fuse Blast Large Tumbler Basket fits 2-3× Fuse build volumes and 50% more parts per cycle.
6. Polish
Polish with Fuse Blast: Optional polishing system upgrade delivers smooth, semi-gloss, dye-ready surfaces.
Formlabs Fuse X1 3D Printer Specifications
- Technology: Selective laser sintering (SLS)
- Build Volume: 330 × 330 × 565 mm | 13.0 × 13.0 × 22.2 in (61.5 L)
- Layer thickness: 110 microns | 0.004 in
- Laser Type: Ytterbium Fiber, 120 W
- Laser Spot Size: 330 microns | 0.012 in
- Throughput: 0.330 sintered kg/hr
- Max Packing Density: 30%+ (volume), 48%+ (mass)
- Material Refresh Rate: As low as 20%
- Materials: Nylon 12, Nylon 11*, Nylon 12 GF**, TPU**, Open Material Mode
- Print Intelligence: AI-powered real-time print failure prevention
- Footprint: 1.3 m^2 / 14.1 ft^2
- Power Requirements: 200-240VAC single phase, 50/60Hz, 50A rating
- Warranty and Services: Production and Self-Service plans available.
Complete 3D Print & Post Processing Solution
Fuse X1 post-processing is a multi-step workflow designed to extract 3D printed parts from a "powder cake," reclaim unused material, and finish the part surface. This process is primarily managed through the Fuse Sift and the Fuse Blast:
Fuse X1 Printer
Fuse X1 is a large-format industrial SLS 3D printer its massive build volume and high packing density enable same-day large parts and 3x the throughput compared to competing platforms. AI-powered Print Intelligence monitors jobs from first layer to final part to reduce failures.
Setup takes about an hour, print-to-print changeover takes minutes, and the same end-to-end workflow handles extraction, powder reclaiming, and finishing — moving parts from printed to polished in as little as 15 minutes.
Fuse Sift X1
The Fuse Sift is used as part of the post-processing stage of the SLS process. Designed to be easy-to-use, the Sifts modular design simplifies the process of using the build chamber for part extraction, powder reclamation and refilling.
No other SLS system on the market provides the same level of functionality from one machine. A negative air pressure system keeps the powder within the Sift for a clean and tidy workspace.
Fuse Blast
Achieve professional, consistent parts that are clean to the touch faster and easier than ever before with Fuse Blast, an easy-to-use, fully automated cleaning and polishing solution for post-processing SLS 3D printed parts.
Streamline your post-processing workflow, empowering you to fully clean a whole build chamber of printed parts in as little as 15 minutes and drastically reducing labor time and cost.
Example Parts
Example SLS 3D printer prototypes and parts in a wide range of materials. Pick on the images below to enlarge
Hands-off Workflow
Fuse Sift X1 turns post-print into a clean, hands-off workflow.
An integrated powder transport system moves used powder from the Sift X1 to the Mix Kit automatically, and integrated compressed air inlet and gun that helps you recover powder from parts in seconds, replacing slow manual brushing.
The sealed glovebox keeps operators and the workspace clean at any build size, while a built-in parts hatch sends broken-out parts straight to a transfer bin to free up the bench. With capacity for 3 to 5 full builds of used powder, Fuse Sift X1 keeps high-volume operations moving without bottlenecking on cleanup.
Powder Transport System
Fuse X1 Vacuum Conveyor is the building block of the powder transport system. One unit on the Fuse X1 loads refreshed powder into the printer, and a second unit moves sifted reclaimed powder from the Fuse Sift X1 to the Mix Kit or mixing setup of your choice.
Additional vacuum conveyors can be used to transport and manage powder as desired to minimize bottlenecks, such as storing powder in large format containers. Each Vacuum Conveyor ships with mounting hardware and a vacuum hose. One Vacuum Conveyor is included with the Fuse X1 and one with the Fuse Sift X1.
Materials available for the Formlabs Fuse X1
Produce lightweight, strong and robust parts. Formlabs SLS powders have been developed to deliver peak performance while optimizing cost per part. Includes Nylon 12, Nylon 11*, Nylon 12 GF**, TPU**
*Available by the end of 2026 **Available by June of 2027
Find the Perfect Materials
We have a complete selection of high-quality materials, specifically chosen for your Formlabs 3D printer.
Industries we work with
TriMech Advanced Manufacturing is used in a wide variety of industries
Architectural Design & Construction
- Model making
- Urban planning
- Concepts
High Tech & Consumer Products
- Aesthetic and function testing
- Concepts and prototypes
- Sales and marketing models
Dental, Medical & Life Sciences
- Anatomical models
- Medical devices
- Orthopedics
- Prosthetics
- Surgical planning models
Industrial Products, Mold Tool & Die
- Jigs, fixtures, and assembly tooling
- Injection molding
- Silicone molding
- Sand and investment casting
- Thermoforming
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