Formlabs has launched the Fuse X1, its first large-format SLS 3D printer, starting at $84,999 as part of a new industrial ecosystem.
Formlabs says that the Fuse X1 delivers production-quality parts in under 24 hours with up to 50 per cent lower cost per part and three-times the throughput of comparable industrial powder bed fusion systems.
Already one of the largest global suppliers of SLS 3D printers with its benchtop Fuse model, launched in 2021, the Fuse X1 is targeting higher throughput and larger parts, putting the likes of EOS, Farsoon and other large format polymer SLS printer makers in its sights. While EOS and Farsoon both have US-based elements, this puts Formlabs in a great position against the current backdrop of tariffs and military spending in 3D printing.
The Fuse X1 3D printer offers automated powder handling, while the compact system has been designed to fit through a standard door, run on single-phase power and operate without need for specialised HVAC. It can be up and running after an hour of installation and is backed by AI-powered ‘reliability features’ for print failure prevention.
The 330 × 330 × 565 mm build volume can manage 30%+ part packing per build (MJF 3D printers roughly 10-15%), and is overseen by Formlabs’ new Adaptive Thermal Control for SLS. This new thermal architecture is designed to maintain stable print conditions across the build chamber. It collects and processes 700 times more thermal data per second than the Fuse 1+ 30W, driving 13 independent thermal zones that deliver, maintain and sinter powder at precise and stable temperatures from the first layer to the last.
Using AI enhanced computer vision, Print Intelligence detects part defects in real time and selectively removes the affected part from the following layers, saving materials and time.
In the four months prior to the announcement, Formlabs states that Fuse X1 units have already printed over 30,000 parts over four months for its Beta testers.
“Since the beginning, Formlabs has worked to build the tools that make it possible for anyone to bring their ideas to life,” said Formlabs CEO Max Lobovsky. “With Fuse X1, we’re bringing industrial-scale SLS printing to a much broader market, making it competitive with traditional mass manufacturing.
“Customers no longer need to spend half a million dollars or dedicate an entire facility to manufacturing production-grade parts quickly and reliably.”
Available for order now, deliveries will begin Q4 2026. Fuse X1 parts will also be available for order for customers in the US starting via its online 3D printing service, Form Now.
