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Large-Format SLS, Streamlined
Formlabs Fuse X1 3D Printer
A powerful industrial SLS 3D printer built for large-format production, with an end-to-end ecosystem that moves parts from print to polish.
Large-Format 3D Printing at 3X the Throughput
The Formlabs Fuse X1 brings a new level of speed and scale to industrial SLS 3D printing.
Built for engineers, manufacturers, and service bureaus, the Fuse X1 supports full-scale production parts, large prototypes, and high-volume end-use components with faster turnaround and a more streamlined workflow.
With a 61.5L build volume and high packing density, the Fuse X1 enables same-day large parts, up to three times the throughput of competing industrial SLS platforms, and up to 50% lower part costs than traditional industrial powder bed fusion systems.
AI-powered Print Intelligence monitors each job to help prevent failures and maximize uptime, while Adaptive Thermal Control and Open Material Mode add the control and flexibility needed for scalable production.
Technical Specifications
| Features | Fuse X1 3D Printer |
|---|---|
| Build volume | 330 × 330 × 565 mm (13.0 × 13.0 × 22.2 in) (61.5 L) |
| Layer thicknesses | 10 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 m² (14.1 ft²) |
| Power requirements | 200-240VAC single phase, 50/60Hz, 50A rating |
*Available by the end of 2026 **Available by June of 2027
A Complete Workflow Built for High-Volume Production
The Fuse X1 is one part of a powerful ecosystem, giving teams an end-to-end workflow from print to finish. It’s designed for fast setup and efficient job changeovers.
Setup takes about an hour, print-to-print changeovers take five minutes, and the complete workflow supports cooling, powder handling, part breakout, reclaiming, and finishing ― moving parts from print to polish in as little as 15 minutes!
The ecosystem consists of:
- The Fuse X1 Build Unit that enables rapid five-minute job changeovers, allowing one build to cool while the next begins printing.
- The Vacuum Conveyor automatically moves powder from the Fuse Sift X1 to the Mix Kit, reducing manual transport and keeping the workspace cleaner.
- The Fuse Sift X1 simplifies part breakout and powder recovery in a sealed, operator-friendly environment, while the Mix Kit blends fresh and reclaimed powder to maintain material consistency and maximize powder reuse.
Together, they give you a scalable workflow that gets the done faster and done right without tedious manual labor.
Fuse X1 Build Unit
The Fuse X1 Build Unit moves prints throughout the Fuse X1 ecosystem ― from the Fuse X1 3D printer to the Fuse Sift X1 to the Mix Kit.
Its wheeled, mobile design makes it easy to move between the Fuse X1 printer and Fuse Sift X1 for part breakout. Blind-mate power and data connectors support ergonomic print changeovers, while the insulated chamber allows printed parts to passively cool outside the printer.
By moving cooling outside the machine, the Build Unit frees up the Fuse X1 printer to start the next print with minimal downtime.
Fuse X1 Vacuum Conveyor
The Fuse X1 Vacuum Conveyor is the building block of the powder transport system in the Fuse X1 workflow.
One Vacuum Conveyor loads refreshed powder into the printer, while a second one moves sifted reclaimed powder from the Fuse Sift X1 to the Mix Kit, or mixing setup of your choice.
Additional Vacuum Conveyors can be added to move and manage powder across high-volume workflows, including storage in large-format containers.
Each Vacuum Conveyor includes mounting hardware and a vacuum hose. One Vacuum Conveyor is included with the Fuse X1 3D printer, and one is included with the Fuse Sift X1.
Fuse Sift X1
The Fuse Sift X1 turns post-print powder recovery into a cleaner, more efficient workflow for large-format SLS production.
An integrated powder transport system automatically moves used powder from the Fuse Sift X1 to the Mix Kit, while the built-in compressed air inlet and gun make it easier to remove powder from parts without slow manual brushing.
A sealed glovebox keeps operators and workspaces clean, and a built-in parts hatch sends broken-out parts directly to a transfer bin to keep the bench clear.
With capacity for three to five full builds of used powder, the Fuse Sift X1 keeps high-volume production moving without cleanup becoming the next bottleneck.
Fuse X1 Mix Kit
The Fuse X1 Mix Kit simplifies powder management by automatically blending reclaimed powder from the Fuse Sift X1 with a fresh supply at the precise refresh rate. An included scale supports accurate mixing ratios for every batch.
Once the material is mixed, the Fuse X1 Vacuum Conveyor loads the material into the printer for the next job.
For high-volume operations, additional Vacuum Conveyors can be added to create more flexibility for powder transfer, storage, and material handling across the entire workflow.
Frequently Asked Questions
The Formlabs Fuse X1 is a large-format industrial selective laser sintering (SLS) 3D printer, designed for production manufacturing, service bureaus, and product development teams. With a 330 × 330 × 565 mm build volume, it delivers up to three times the throughput of competing industrial systems, while maintaining production-quality results.
The Fuse X1 delivers up to 50% lower part costs than traditional industrial powder bed fusion systems through high packing densities, efficient powder reuse, automated workflows, and reduced labor requirements. For many applications, it can offer a cost-effective alternative to injection molding for tens of thousands of parts.
The Fuse X1 supports Nylon 12 and Open Material Mode at launch, with Nylon 11 planned by the end of 2026 and Nylon 12 GF and TPU expected by June 2027. This growing material portfolio allows manufacturers to produce durable functional prototypes and end-use production parts.
The Fuse X1 ecosystem includes the Fuse X1 3D printer, Fuse X1 Build Unit, Fuse Sift X1, Vacuum Conveyor(s), Mix Kit, PreForm software, and Fuse Blast finishing system. Together, these solutions create a streamlined workflow from print preparation and production through powder recovery and post-processing.
The ecosystem automates key production steps to reduce labor and maximize uptime.
- The Fuse X1 Build Unit enables five-minute print changeovers.
- The Vacuum Conveyor automatically transports powder.
- The Fuse Sift X1 simplifies part extraction and powder recovery.
- And the Mix Kit blends fresh and reclaimed material.
This integrated workflow helps manufacturers move from printing to finished parts faster while reducing waste and manual handling.