Formlabs Unveils Fuse X1: Industrial Large-Format SLS 3D Printing at a Fraction of the Cost
Formlabs, the world’s largest supplier of professional SLA and SLS 3D printing systems, today announced the Fuse X1, a new industrial large-format selective laser sintering (SLS) ecosystem designed to make high-throughput additive manufacturing more accessible to manufacturers, engineering teams, product developers, and service bureaus.
Early access customers, including Tesla, Radio Flyer, and Autotiv Manufacturing, have already used Fuse X1 to accelerate product development and scale production, printing more than 30,000 parts in just a few months.
“Since the beginning, Formlabs has worked to build the tools that make it possible for anyone to bring their ideas to life,” said Max Lobovsky, co-founder and CEO of Formlabs. “With Fuse X1, we’re bringing industrial-scale SLS printing to a much broader market, making it competitive with traditional manufacturing without the cost and complexity of legacy systems.”
Starting at $84,999, Fuse X1 delivers production-quality parts in under 24 hours, with up to 50% lower cost per part and up to three times the throughput of comparable industrial powder bed fusion systems. The compact ecosystem combines large-format printing, automated powder handling, AI-powered reliability features, and an intuitive workflow while operating on standard single-phase power.
Key capabilities include:
• 330 × 330 × 565 mm build volume
• More than 30% packing density
• Up to 50% lower part costs than legacy industrial SLS and MJF systems
• Less than half the floor space requirements of comparable systems
• Same-day production of large parts and up to 3× greater throughput
• AI-powered Print Intelligence failure prevention
• One-hour installation and five-minute print changeovers
Fuse X1 introduces two new technologies: Adaptive Thermal Control and AI-Powered Print Intelligence.
Adaptive Thermal Control processes 700 times more thermal data per second than the Fuse 1+ 30W and manages 13 independent thermal zones to maintain stable print conditions throughout the build. This enables packing densities above 30%, compared with the typical 10–15% recommended for MJF systems, allowing more parts per build and significantly higher throughput.
Print Intelligence combines computer vision and real-time thermal imaging to monitor every layer during printing. The system detects anomalies and defects as they occur and can isolate affected parts, reducing waste and preventing full-build failures.
The Fuse X1 ecosystem includes the Fuse X1 printer and Build Unit, Fuse Sift X1 for powder recovery, the Fuse X1 Vacuum Conveyor for automated powder transport, and a new high-capacity Fuse Blast configuration for post-processing.
Tesla is using Fuse X1 for product development, tooling, and end-use parts production. Radio Flyer has reduced prototype lead times from months to days, enabling faster design iterations. Autotiv Manufacturing expects to achieve ROI up to five times faster than with comparable SLS systems due to lower costs and higher throughput.
In the four months prior to launch, Formlabs customers printed more than 30,000 parts on Fuse X1 systems. Customers in the United States can also order Fuse X1-produced parts through Formlabs’ online manufacturing service, Form Now.
Fuse X1 will make its public debut at the Reindustrialize Summit on June 16 in Detroit, Michigan.
Media Contact: press@formlabs.com
