Formlabs Fuse X1 Ecosystem

High-Volume SLS Printing, Simplified

The Formlabs Fuse X1 ecosystem is a complete industrial selective laser sintering (SLS) solution designed to deliver high-throughput production, streamlined powder management, and efficient post-processing at scale. Centered around the Fuse X1 printer, the ecosystem combines intelligent automation, large-format printing capabilities, and integrated material handling to help manufacturers, engineers, and service providers move from design to finished parts faster than ever. From printing and cooling to powder recovery, mixing, and finishing, each component works together to minimize downtime, maximize material efficiency, and support consistent production of high-quality end-use parts.

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Formlabs | Fuse X1

Fuse X1 is a large-format industrial SLS 3D printer, built for engineers, manufacturers, and service bureaus looking to produce large prototypes and high-volume end-use parts with a faster turnaround. Its massive  build volume and high packing density enable same-day large parts and 3x the throughput compared to competing platforms.

 

AI-powered Print Intelligence monitors jobs from first layer to final part to reduce failures. Setup takes about an hour, print-to-print changeover takes minutes, and the same end-to-end workflow handles extraction, powder reclaiming, and finishing — moving parts from printed to polished in as little as 15 minutes.

A CLOSER LOOK

EXPLORE THE FUSE X1 ECOSYSTEM

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Formlabs | Fuse Sift X1

Fuse Sift X1 is a large format powder recovery station that turns post-print into a clean, hands-off workflow. An integrated powder transport system moves used powder from the Sift X1 to the Mix Kit automatically, and integrated compressed air inlet and gun that helps you recover powder from parts in seconds, replacing slow manual brushing.

 

The sealed glovebox keeps operators and the workspace clean at any build size, while a built-in parts hatch sends broken-out parts straight to a transfer bin to free up the bench. With capacity for 3 to 5 full builds of used powder, Fuse Sift X1 keeps high-volume operations moving without bottlenecking on cleanup.

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Formlabs | Fuse X1 Build Unit

The Fuse X1 build unit contains and transports prints throughout the Fuse X1 ecosystem.

 

It is wheeled and mobile to easily move between the Fuse X1 during printing and Fuse Sift X1 for breakout, with blind-mate power and data connectors for ergonomic print changeovers.

 

An insulated chamber allows the print to passively cool outside of the printer, enabling the next print to start with minimal downtime.

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Formlabs | Fuse X1 Vacuum Conveyor

Fuse X1 Vacuum Conveyor is the building block of the powder transport system. One unit on the Fuse X1 loads refreshed powder into the printer, and a second unit moves sifted reclaimed powder from the Fuse Sift X1 to the Mix Kit or mixing setup of your choice.

 

Additional vacuum conveyors can be used to transport and manage powder as desired to minimize bottlenecks, such as storing powder in large format containers. Each Vacuum Conveyor ships with mounting hardware and a vacuum hose. One Vacuum Conveyor is included with the Fuse X1 and one with the Fuse Sift X1.

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Formlabs | Fuse X1 Mix Kit

Fuse X1 Mix Kit simplifies powder management by automatically blending reclaimed powder from the Fuse Sift X1 with fresh supply at the precise refresh rate. An included scale ensures an accurate mixing ratio for every batch.

 

Once 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 for additional flexibility to transfer and store powder as desired.

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Formlabs | Fuse Blast High Capacity Kit

Scale your post-processing throughput with the Fuse Blast High Capacity Kit, a drop-in upgrade for Fuse Blast that processes over 50% more parts per cycle than the standard basket. It's the recommended configuration for Fuse X1 users and multi-Fuse 1 Series fleets running large, frequent batches.

 

A wider 400 mm opening makes loading and unloading easier and more ergonomic, while the added volume prevents the overcrowding that can damage parts mid-cycle. Swap it into your existing Fuse Blast in minutes, with no tools or machine modifications required.

 

Fuse Blast High Capacity Kit pairs the Large Tumbler Basket with an extra Fuse Blast Large Tumbler Basket Liner Kit, so high-volume users can replace the liner without any downtime waiting on a separate order.

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