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Formlabs Fuse 1

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Formlabs Fuse 1

Formlabs Fuse 1 & Sift SLS Printer

The hugely respected desktop 3D printer manufacturer, Formlabs, has recently launched a Selective Laser Sintering (SLS) system. Reaching levels acceptable for industrial applications, this benchtop printer has incorporated every easy-to-use hardware and software option available to give the user a highly efficient SLS 3D printer.

Printing in Formlabs’ own Nylon 12 powder unique to the Formlabs Fuse 1, users can expect parts exhibiting fine detail along with high environmental stability and strength. Ideal features for functional prototypes and parts with complex geometries.

Key Features

A 30% material refresh rate means you can print with up to 70% recycled powder, indefinitely. Fuse Sift’s sieve filters out particles to be remixed with new powder and reused in future prints.
A negative air pressure system within the FUSE Sift keeps powder inside while enabling open access and easy cleanup.
Fuse Sift will dispense and mix used and new powder automatically so you can reduce waste and control your powder supply.
Reduce downtime by transferring modular build chambers and powder cartridges between the Fuse 1 and Fuse Sift for a nonstop, cyclical workflow.
The Fuse Sift includes a set of finishing tools to help you clean excess powder from parts with ease.

Powder recovery

After the part is built, recovery of the powder is by vacuum extraction in the Fuse Sift recovery station. This unit is separate to the printer and ensures maximum safety in the environment containing the powder. The required operational level of the anti-static dissipative vacuum is NFPA 652 – Class II Division 2. Using accessories such as the hose, the vacuum can also be used to clean the build chamber and sifter mesh as well as keeping the general area clear of loose powder.

Powder cartridge

To enable continuous printing, it is possible to transfer the powder cartridges and build chambers between the Fuse 1 3D Printer and the Fuse Sift recovery station. Powder from the Fuse Sift can be recycled into the Fuse 1 hopper, with the powder cartridge doubling-up as a mixing container to combine the new and recycled powder.

Safe and efficient powder recovery.

Fuse sift combines filtration and powder recovery in one machine. Produce fully functional parts with a 30% powder refresh rate -with unlimited cycles. This means printing can be done using 70% of recycling materials. Building parts as complete assemblies reduces the time spent on removing the powder in the Sift. It will also reduce the time involved to post-process the parts. Pack your parts as many as possible and create as many possible items.

Easy post-processing for SLS

The Fuse Sift combines parts extraction, powder recovery storage and mixing in one freestanding device. Fuse 1 has a material refresh rate of up to 30% which allows printing with 70% recycled materials indefinitely. The Fuse 1 represents the most functionality offered in a single SLS system on the market. It can extract and mix used sifted powder and fresh powder together, as well as storing, dosing and filling up the powder cartridge ready for use. Fused Sift can recycle a greater amount of used powder that makes your processes faster while minimising the risk of contamination.

Reduce post-processing time

Building parts as complete assemblies reduces the time spent on removing the powder in the Sift. It will also reduce the time involved to post-process the parts.

More volume, More parts

Selective laser sintering gives users free access to the entire build volume without needing any space for supports because the powder supports the parts independently. With a maximum build size of 15.9 x 15.9 x 29.5 cm, the Fuse 1 allows for quick production of multiple components.


The Fuse 1 is designed for minimal upkeep. A full colour touchscreen interface guides you through every step of printing and maintenance.


With reduced equipment cost, affordable material, and efficient powder recycling, the Fuse 1 is the smart choice for industrial quality SLS 3D printing.


From print setup to powder recovery, our easy-to-use hardware and software are designed to maximize your efficiency at every step of the process.

Fast, simple print setup.

Use Formlabs PreForm print preparation software (free to download and try) to import STL or OBJ part files, orient and arrange models, estimate print times, monitor your printers, and upload job files.

PreForm’s part packing algorithms can automatically arrange multiple models in a build.

Compact Selective Laser Sintering made manageable

During setup and printing, an intuitive Touch UI walks you through every step.

The touchscreen displays a live stream of the print bed so you can watch each new layer take shape. This camera view is also available from your computer in PreForm so you can monitor your print without leaving your desk.

Track printers, teams, and supplies via the cloud-based Dashboard.

Reliable, consistent printing.

Selective Laser Sintering 3D printing fuses nylon powder layer by layer. The unused powder supports the parts during printing so you can create complex, interconnecting designs with no need for support structures.

With patent pending Surface Armor technology, a semi-sintered shell that prints around the surface of the part, the Fuse 1 provides competitive mechanical properties and surface finish without the prohibitive cost or hassle of competitor systems.

Safe, efficient powder recovery.

Our all-in-one powder recovery station, Fuse Sift, combines part extraction, powder recovery, storage, and mixing in a single device.

Produce fully-functional parts at a 30% powder refresh rate—with unlimited cycles. This means you can print with up to 70% recycled powder.

Fuse Sift will dispense and mix used and new powder automatically so you can reduce waste and control your powder supply.

Got a question about our products? Call 44 (0) 1295 672600 or click here to get in touch.

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