Most 3D printers that utilise this technology specialise in metal 3D printing. The system as a whole is very efficient and we had a blast using it. But, the Fused Filament Fabrication 3D printers that can print it offer limited performance. The Formlabs Fuse 1 is aSelective Laser Sintering (SLS) 3D printer. It is, however, a niche product that's engineered for industrial applications. 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. From 3D-printed figurines for students to quantum dots and nanocomposites, Olga Ivanova is a force to be reckoned with in the AM universe. Overall, the Fuse 1 has given our clients the freedom and ability to save big on setup costs, fulfillment time, and unsold back stock. 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. 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. Simply attach the filled cartridge to the rotation system and activate the mechanism for ten minutes via the touchscreen. Connectivity options include USB, Wi-Fi, and ethernet, so feel free to take your pick. Surface Armor was developed after Formlabs noticed that parts printed with low energy-density showed no evidence of a rough surface texture. Then the part is moved over to the middle of the workspace where the sieve can be found this is where the powder removal takes place. To complement the 3D printer, Formlabs also launched the Fuse Sift, a post-processing system for use with the Fuse 1. On the electronics side, the Fuse 1 has a 10.1 full-color touchscreen on the front (1280 x 800 resolution). 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. Photo by 3D Printing Industry. */, 64.5 (w) x 68.5 (d) x 107 cm (h) (165.5 cm with stand), 145.5 (w) x 149.5 (d) x 167.5 cm (h) to allow access to the front and sides, 4.01 mrad beam divergence (nominal, full angle), 2022 CREAT3D Ltd. All other rights reserved. SLS has practical advantages over FFF or SLA for design and engineering applications. On the other hand, the model car is a 1954 MG TF. Ensuring that you choose the right additive manufacturing solution for your application is our priority and we know that one size rarely fits all. While this may sound like a nightmare for the more advanced users out there who enjoy tinkering around in the settings, it means that theres no room for human error. There's no need for support structure on any model design, and you can print consolidated models in one sitting. 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. The average standard deviation also came in at only 0.0395mm, which is a fantastic result. Due to the fineness of the powder particles, its also recommended to wear adequate PPE at all times when exposed to airborne powder. The system is intended as an accessible offering for engineers, designers, and manufacturers seeking both functional prototyping and end-use polymer production all at a fraction of the cost of traditional SLS competitors. All in all, the Fuse Sift does everything it promises to and works like a charm. The standard cleaning process requires a quick wipe with ethanol. 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. 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. It uses Selective Laser Sintering 3d printer technology. 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"). 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. This means you can print models as one part, rather than in several separate parts for assembly. Available today, starting at $18,499 for the printer or $31,845 for the complete setup including the Fuse Sift, Formlabs claims the Fuse 1 enables users to take control of their entire product development processfrom iterating on the first concept design to manufacturing ready-to-use products in production-ready nylon. 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. 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 scaling down SLS 3D printing. All of the holes were also fabricated successfully with true-to-size diameters and dimensions. The Formlabs Form 2, the best desktop SLA 3D printer on the market today, doesn't support nylon for this reason. The Form 1 redefined stereolithography (SLA) printing for the additive manufacturing industry 10 years ago, and now the Fuse 1 is bringing the same reliability and accessibility standard that Formlabs customers expect of industrial 3D printing, said Max Lobovsky, CEO and co-founder of Formlabs. At a minimum, you should always have a mask when using Sift or a media blaster. Formlabs carefully crafted package is perfect for those seeking an accessible but comprehensive entry into SLS 3D printing. 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 Fuse 1 is compatible with the Fuse Sift for a streamlined process. 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. 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. With the Fuse1, you can also print with up to 50 per cent recycled powder. Nylon 11 has a 48MPa ultimate tensile strength rating, with 35 per cent elongation at break. 3615 Superior Avenue
In the worst case, 99.6% of the 65mm circles fabricated by this 3D printer will be between 64.74mm and 65.21mm. To then refill the Fuse 1 3D printer, the user must fill an empty powder cartridge in the cartridge drawer of the Fuse Sift. This has proven to be a highly useful workflow overview tool. It is the first 3D printer to offer industrial-grade SLS performance in a compact, benchtop-friendly package. For those that have used Formlabs systems before, this is the same slicing software that complements the companys SLA 3D printers. Once a build is complete, youll also need to let it cool down before transferring the build chamber over to the Fuse Sift. As it stands, Fuse 1 users are limited to printing Nylon parts but Formlabs is currently working on expanding its powder offering. Formlabs provides its own slicing software for use with the Fuse 1 PreForm. Not only will the Fuse 1 help Formlabs expand its own footprint in the industrial 3D printing space, the company feels it will substantially expand the market size for industrial 3D printing as a whole by offering truly production-ready 3D printing to an entirely new set of customers. 3D Printing Industry reviews the Formlabs Fuse 1 3D printer and Fuse Sift post-processing system. 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. Accessible radiation is within Class 1 limits, Pressure controlled two stage filtration (replaceable HEPA and carbon mediums). 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. 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. 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. 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. 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. The nearest thing to nylon it prints is Tough Resin. The Fuse 1's layer height of 0.11 mm provides smooth surface finishes and detail, while its build area of 165 mm x 165 mm x 300 mm gives you the creative space to create large objects without sacrificing detail. It's also heat resistant andhighly resistant to abrasion and chemicals such as acids and alkalis. 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.. Additive manufacturing is thriving and continues to gain momentum with successes across diverse applications. You probably would be purchasing the Fuse 1 as part of a larger prototyping facility, whereas the Form 2 could be your first 3D printer. The print preparation program is easy to use with a polished, clutter-free user interface. We visited the offices of UK-based 3D printer supplier Solid Print3D to review both of these devices.Prefer to watch a video of this review? 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. With final parts that combine strength, flexibility, and detail, Fuse 1 prints are ready for rigorous functional testing, prototyping or end-use parts. As far as limitations and shortcomings go, we thought the option to leverage third-party 3D printing powders wouldve been great. The Fuse 1 prints with nylon powder exclusively. 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! You can make do by making your print in pieces, and then assembling, however, sometimes you'll just need a larger build area. 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. 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 is, in fact, the first Formlabs 3D printer designed from the ground up to print with nylon. By studying the normal distribution of the concentric circles diameters (20mm, 65mm, 100mm), we can say that the printer offers sufficient repeatability when the mean of the difference is under 0.1mm and the standard deviation is under 0.05mm. Much like the Fuse 1, the Sifts user interface is expertly crafted for simplicity and elegance, all while maintaining its comprehensiveness. 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. Company no. Weighing only 114 kg, this 3D printer is light enough to move around your workspace but big enough to print your largest designs. For the best experience on our site, be sure to turn on Javascript in your browser. SLS 3D printers use a high-powered laser to selectively 'sinter' material. The store will not work correctly in the case when cookies are disabled. The Fuse 1 is an impressive 3D printer, both in isolation and on the spec sheet.
The nylon powder is proprietary, so it's made by Formlabs to the highest possible specification.
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. You are free to manage these via your browser settings at any time. With the Fuse 1, you can 3D print high-performance machine parts, tools, living hinges, jigs, jaws, and fixtures. Easy. It contains all of the tools necessary for unpacking the build, cleaning the parts, and reusing unsintered powder. 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. 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. Whether that's to create jigs, jaws and fixtures, or casings for consumer electronics, there's always something. 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 Fuse Sift stress-free post-processing. And at the other end of the scale, you can print beautifully-detailed models. Samples printed with Nylon 12 powder have been evaluated in accordance with ISO 10993-1:2018, and have passed the requirements for the following biocompatibility risks: EN ISO 10993-5:2009; ISO 10993-10:2010/(R)2014; and ISO 10993-10:2010/(R)2014. Once mixed, the homogenous powder cartridge can be used to fill the hopper of the Fuse 1. The company notes that the cheapest commercial SLS 3D printer currently on the market costs around $200,000 and prices can reach as high as $800,000 to $1,000,000. 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. 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. 08416238, This site uses cookies. Once the user transfers the Fuse 1s build chamber to the Fuse Sift, the printed part and the mountain of unfused powder (aka the cake) emerge from the left side of the workspace with the help of an elevator. Subscribe to the 3D Printing Industry newsletter for the latest news in additive manufacturing. Complete set up of Fuse 1 system starts from 24,383.00 - view packagesorcontact usto build your own package. 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. Formlabs Fuse Sift, powder recovery system. To aid with the powder removal step, users will find it handy to make use of the vacuum cleaner included in the box. You can print housings, casings, shells, and electronic components. Selective Laser Sintering is one such option, and Formlabs thinks so too. Our measurement devices are accurate to 0.015mm. 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. 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. The Fuse 1 offers the following features: - High throughput - High productivity - High uptime - Proven results - Repeatability - Low cost of ownership. 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.
Once the proper safety measures have been put in place, its important to appreciate that SLS is a hot process. This is because of the technology, not the material; a mechanical print head, as all FFF 3D printers have, limits the geometries that are possible during the print process. Stereolithography is equally limited, but in a different way; nylon resins are expensive and prone to irregular performance. It's also important to point out that the Form 2, Formlabs' SLA 3D printer, does not support nylon. The Fuse 1 is a desktop 3D printer that prints high-resolution prototypes, jewelry, and art with innovative engineering and a beautiful design. Well take a deeper dive into each of these stations and explain how they all work. From print setup to powder recovery, the easy-to-use hardware and software are designed to maximise efficiency at every step of the process. 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. 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. 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. The Fuse 1's potential applications are largely dictated by its print material, nylon. Visit 3D Printing Jobs for a selection of roles in the industry. 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. One of the most striking things about the Fuse 1 is its compact frame. 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. The Fuse 1 is more targeted at a small- to medium- to large-sized business. The 3D printed puzzle cube was undoubtedly one of the most spectacular objects we were able to print with the Fuse 1. Based in Somerville, Massachusetts, Formlabs is undoubtedly one of the biggest names in professional-grade SLA 3D printing. In other words, this isn't a gadget for an office user, but a serious piece of kit for engineers. Formlabs improves on SLS with the Fuse 1 and Fuse Sift, bringing it within reach for all companies through affordability and ease of use. You can print gears, sheaves, and sprockets for industrial machinery. As we have no ties to a single manufacturer, we are proud to able to provide expert impartial advice to you and samples from our printers direct to you to assess the print quality and material properties. Compared to other SLS 3D printers, the system is highly space-efficient, measuring just 645 x 685 x 1070mm (1655mm tall with the stand). Buy the Fuse 1 and Fuse Sift here. In the best case, 99.6% of the 100mm circles manufactured by this 3D printer will be between 99.93mm and 100.07mm. That makes it super-tough. Industry News & Resources through the pandemic, Online Community for Members to Engage & Share Knowledge. There has to be a better way to print nylon, then. #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. , East Building 44, 5th Floor, Certified Manufacturing Associate (CMfgA), Certified Manufacturing Technologist (CMfgT), Canadian Manufacturing Technology Show (CMTS), Montreal Manufacturing Technology Show (MMTS), North American Manufacturing Research Conference (NAMRC), Western Manufacturing Technology Show (WMTS). Used in conjunction with the Fuse 1, the Fuse Sift is an automated post-processing system designed to depowder polymer 3D printed parts. Sources: SLS Guide (Formlabs), Fuse 1 (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. Looking for a career in additive manufacturing? 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. Special thanks to Solid Print3Dfor allowing us to visit their facilities and perform the testing required for this review. 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. Fuse 1 made it to the market at a very low price compared to other industrial printers. 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. The companys cloud-based Dashboard platform also enables users to track printers, teams, and supplies from anywhere. 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The IR sensor is what measures the temperature of the powder while the cassette is the element through which the infrared waves and laser beam pass through to reach the powder bed. You can also stay connected by following us on Twitter, liking us on Facebook, and tuning into the 3D Printing Industry YouTube Channel. Nylon isabrasion resistant, heat resistant, and has a low friction coefficient. 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. A negative air pressure system keeps powder inside while enabling open access and easy cleanup. Unsurprisingly, the Fuse 1 delivered once again both the electronics casing and the joining component were printed virtually flawlessly. It's also extremely strong. It was designed, printed, and painted by Solid Print3Ds Benjamin Keyser. Additionally, the build chamber is modular in that it can be removed in its entirety. 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). 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. 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. 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. 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. SLS allows designers to create complex interior components using unique geometries, and it allows engineers to reproduce parts with precise replication. Here, users can fill the Fuse Sift with fresh Nylon powder to be recycled with the used powder previously reclaimed at the sieving station. Here's the full specs for Nylon 12 and Nylon 11: Nylon 11 and 12 are both single component powders. On the software performance side, theres not much to complain about at all. 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. So, this is a heavy 3D printer, but rest assured that translates to rock solid performance. To achieve the full range of motion, we did have to wiggle around the joints to get all of the loose powder out but once we broke the mechanism in, it performed as intended with the smoothest of movements. Currently, Formlabs recommends a material refresh rate of 30% 50% (this means using 30% fresh PA12 powder and 50% fresh PA11 powder). 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. All Rights Reserved. Then theres the Fuse Sift. Once the bulk of the powder has been removed from the parts, you may still find that small nooks and crannies will be laden with unfused powder. The PreForm slicer is fast, bug-free, and responsive, just how we like it. Similarly, the printer did an excellent job with the planetary gear system. One of the main selling points of PreForm is that it only has one set of predefined process parameters that cant be modified. Each of the gears was defect-free, sported clean surfaces, and meshed well with the rest of the assembly. We recommend moving this block and the preceding CSS link to the HEAD of your HTML file. So, I think thats the main difference that we see, but within that, there are already people who are reserving the product, from medical product development to education. Copyright 2022 Printlitic. 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. It makes quick work of the powder that will inevitably scatter all over the workspace, so be sure to give the Sift (and Fuse 1) a thorough cleaning after every build. 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. Selective laser sintering uses a laser to precisely fuse nylon powder into lightweight, robust parts. 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. So, if you want to 3D print with nylon, the Fuse 1 is for you. Finally, we tried our hand at a number of dynamic print tests with moving parts a functional suspension system, a puzzle cube, and a planetary gear system.
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