Fuse X1 Keynote
For years, getting a large SLS part meant one of two things: buy a six-figure industrial printer, or split your part into sections, print them separately, and glue them back together. Large-format, production-quality selective laser sintering (SLS) stayed out of reach for most teams — until now.
Today, Formlabs launched the Fuse X1, its largest SLS 3D printer to date, with a build volume 8x bigger than the Fuse line. Form Now is already printing on it. So you can order large, production-quality SLS parts today in one piece, dimensionally accurate, and shipped to you, before you even get your hands on a Fuse X1 yourself.
Build Big — Parts Up to 713 mm, in One Piece
With a 330 × 330 × 565 mm build volume and a maximum part length of 713 mm, the Fuse X1 prints large parts whole. Parts that used to be cut and split across many builds now can be done in one.
When Radio Flyer prototyped its Flyer Loop cargo eBike, the frame took 19 separate builds, then days of gluing, Bondo, and paint. Now the entire frame prints in a single build.
“With Fuse X1, we can now print an entire Flyer Loop cargo ebike overnight and be gluing it together the next day. So we went from two months to two weeks to a couple of days.” — Agostino LoBello, Product Development Engineer, Radio Flyer
Parts That Come Off True
A large part is only useful if it holds its shape. Fuse X1 heats the build evenly from the first layer to the last, so large, flat, and complex parts come out dimensionally accurate, without the warping that can creep in on other large-format powder-bed printers. Fuse X1 can also achieve over 30% volume packing density (48%+ by mass), a level of packing freedom that's out of reach for any competing large-format SLS and MJF printers.
Radio Flyer finds that parts come off the Fuse X1 dimensionally accurate, slotting together without filing or sanding.
“When you print something on Fuse X1, it comes off the printer and fits together without additional filing or sanding or post-processing, and that’s just so satisfying.” — Agostino LoBello, Product Development Engineer, Radio Flyer
Geometric Freedom
SLS builds parts in a bed of powder, so it needs no support structures. That means design freedom: thin walls down to about half a millimeter, internal channels, living hinges, lattices, and intricate shapes that are difficult or impossible to mold or machine. Send us the geometry you actually want, not the one your process forces on you.
From One Part to Thousands
Need a single prototype, or thousands of identical end-use parts? The Fuse X1 packs builds densely, so Form Now can handle one-offs and full production runs from the same file. Tesla prints tens of thousands of end-use parts a month on the Fuse X1. Now, that same capability is available to you through Form Now, with no machine and no minimums.
How It Works at Form Now
1. Upload your large model.
2. Select Fused Nylon 12 Powder as the material.
3. We print it on the Fuse X1 and ship it to you directly.