Formlabs Fuse 1+ 30W 3D printer: technical specifications and price

3D printer manufacturer Formlabs launched a new three times more powerful successor to the Fuse 1, its first desktop Selective Laser Sintering (SLS) system.

The Fuse 1+ 30W, is Formlabs’ latest foray into SLS 3D printing and features several upgrades, including a 30-watt laser, designed to facilitate faster production of parts from new, high-performance materials. With these enhancements, Formlabs says the system will enable its key professional designer users to begin producing parts in-house in less than 24 hours when delivered in late August 2022.

Formlabs extension and the SLS 3D printing market

Created in September 2011 by three MIT Media Lab students, Formlabs is primarily known as a developer of stereolithographic (SLA) 3D printers and materials than SLS ones. The company’s ever-evolving SLA portfolio, which enables it to meet the needs of customers ranging from designers to dentists and clinicians, currently includes the Form 3+, Form 3L, Form 3B+ and Form 3BL.

Formlabs has carved out a significant share of the SLA market, selling over 100,000 SLA 3D printers. Today it faces fierce competition as resin 3D printing has become increasingly commercial due to the proliferation of lower cost LCD systems, primarily from China. A similar pattern played out in the FFF world, with high early prices followed by a boom in more affordable 3D printers; a trend no doubt accelerated by Dr. Adrian Bowyer’s RepRap project.

One way to stay ahead of the competition is to keep moving. And Formlabs has moved to SLS, launching Formlabs Fuse 1 and Fuse Sift in January 2021. Parallels can be drawn with prusa diversification, adding SLA to FFF to its product portfolio with the Original Prusa SL1S SPEED resin 3D printer.

Speaking of the launch, CEO Max Lobovsky said, “Since launching the Fuse 1 in January 2021, Formlabs has single-handedly expanded the SLS market, accounting for over 50% of SLS printer sales during that time.”

“With the Fuse 1+ 30W, we are pushing SLS 3D printing to new heights by delivering truly fast, high-throughput SLS printing at an affordable price for businesses. In total, Formlabs has sold over 100,000 professional SLA printers – more than any other 3D printer manufacturer – and the Fuse 1+ 30W allows us to similarly dominate the SLS market.

Chris Connery, VP of Global Analytics and Research at analysts THE CONTEXT expands on this data, “looking at all SLS printers regardless of price and build volume and looking at only SLS (excluding HP’s MPF, Stratasys’ SAF and other powder bed fusion technologies from polymer), Formlabs indeed had the first overall unit volume market share Q1’21-Q1’22 with 49.8%.When machine price is used to weight SLS market share to then display the system revenue share (unit x price), EOS achieved the top market share during this period with 32% (with Formlabs as the #3 player in SLS system revenue).If ALL system shipments polymer powder bed fusion solutions are included, so Formlabs still held the top market share at 38%, followed by HP.”

Continuing, the analyst adds, “Certainly credit goes to Formlabs for championing this new class of benchtop SLS printers, but it’s also important to properly position these small machines as a new class. CONTEXT tends to quantify the printer market through the ASTM process (to then aggregate into MJF, SLS, SAF, etc. in Polymer Powder Bed Fusion) and by our price classes INDUSTRIAL ($100,000+), DESIGN ($20 $000 – $100,000), PROFESSIONAL ($2.5,000 – $20,000), PERSONAL (less than $2.5,000), and KIT&HOBBY (defined by DIY assembly). As such, HP was the biggest player in polymer powder bed fusion during this period in the INDUSTRIAL and DESIGN price categories, with Formlabs topping the PROFESSIONAL space (far ahead of #2 sinterity).

An automotive part 3D printed from 11 CF nylon powder on Formlabs new Fuse 1+ 30W system. Photo via Formlabs.

Power up with the Fuse 1+ 30W

As highlighted in our Fuse 1 3D printer review, Formlabs’ premier SLS system is designed to provide engineers and designers with an affordable and accessible way to create working prototypes and parts. Building on these foundations, the Fuse 1+ 30W includes a number of new and improved components, which allow it to process a wider range of powders and produce parts twice as fast. In addition to a more powerful laser, the machine owes its increased speed to a new galvanometer system, which allows it to reach scanning speeds of up to 12.5 meters per second.

The Formlabs Fuse 1+ 30W 3D printer has the same 165 x 165 x 300mm build volume as before, but its new active powder handling system now makes it compatible with industrial-grade materials. The system is also equipped with a nitrogen purge option which the company says allows it to process them in a way that results in parts that have “competitive properties with [those of] industry leaders.

To showcase the capabilities of the Fuse 1+ 30W, Formlabs has already released case studies in which it was used to make various cycling and automobile parts. In one example use case, the company found it was able to produce shaft couplings 52% faster than the Fuse 1. In another, meanwhile, it reduced delivery times bike seats by 24%, proving its value as a design validation and stopgap. creative tool.

If used with the Fuse 1+ 30W, Formlabs also states that its 11 CF Nylon Powder is ideal for creating lightweight yet rigid parts that can withstand repeated impact. When used to produce plastic alternatives to metal spare parts, for example, the company says its material allows users to harness the best of nylon and carbon fiber and produce products at the both very rigid and resistant.

In practice, Formlabs believes its new system could be adopted by existing SLS users looking to “decentralize their 3D printing operations” without duplicating costs. Likewise, the company expects the enhanced capabilities of the Fuse 1+ 30W to make it ideal for producing a much wider range of spare parts, as well as industrial fixtures, jigs and tools.

An engineer using the new Fuse 1+ 30W 3D printer from Formlabs.  Image via Formlabs.
An engineer using the new Fuse 1+ 30W 3D printer from Formlabs. Photo via Formlabs.

Technical specifications and prices

Below are the technical specifications of the new Fuse 1+ 30W 3D printer. The system is available to order now, with prices starting at $27,499, and shipping is expected to begin in late August 2022.

Formlabs Fuse 1 Formlabs Fuse 1+ 30W
Technology Selective Laser Sintering Selective Laser Sintering
Build volume 165 x 165 x 300mm 165 x 165 x 300mm
Layer thickness 110 micron 110 micron
type of laser Ytterbium fiber 10W Ytterbium fiber 30W
Laser spot size (FWHM) 200 micron 247 micron
Build a room Modular (Fuse 1 and Fuse Sift compatible) Modular (Fuse 1 and Fuse Sift compatible)

To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry Bulletin or follow us on Twitter or like our page on Facebook.

For a deeper dive into additive manufacturing, you can now subscribe to our Youtube channel, with discussions, debriefs and photos of 3D printing in action.

Are you looking for a job in the additive manufacturing industry? Visit 3D printing works for a selection of roles in the industry.

The featured image shows an engineer using the new Fuse 1+ 30W 3D printer from Formlabs. Photo via Formlabs.

Wiley C. Thompson