Formlabs Fuse X1

Industrial SLS Made Accessible

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The Formlabs 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.
Ready to revolutionize your manufacturing process?
‍Order your Formlabs Fuxe X1 today and learn more about the ecosystem.
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Why Choose the FormLabs Fuse X1

Build Big

Produce full-scale production-quality parts in a massive build volume or run production builds at over 30% packing density to manufacture thousands of end-use parts in days, not weeks.

Low Part Cost

Fuse X1 delivers up to 50% lower part cost than legacy powder bed fusion systems in less than half the floorspace. Fuse X1 is cost-competitive with injection molding for tens of thousands of parts.

Productive

Fuse X1 fits through a standard door, doesn’t require facility retrofit, and installs and prints on day one. An intuitive touchscreen guides you, while the build unit enables 5-minute changeovers.

Fuse X1 Workflow

1. Prepare

Auto-pack, optimize, and organize in PreForm: Orient, hollow, or label models, estimate print times, and automatically pack parts for optimized density, reducing print time and limiting waste. Import STL, OBJ, 3MF, or models directly from a wide range of CAD applications.

2. Print

Print large parts in hours, not days: Most
large builds complete under 24 hours, with
same-day large parts in 5 hours. Print
Intelligence detects and masks anomalies in
real time to protect yield

3. Swap

5-minute print changeovers with the Fuse
X1 Build Unit: Roll one build unit out, roll
the next one in, with blind-mate power and
data connectors. Insulation allows natural
cooling inside the unit, so the printer can
start the next job.

4. Unpack

Hands-off powder recovery with Fuse Sift X1: Integrated compressed air, sealed glovebox, and parts hatch keep breakout clean and fast. Capacity for 3 to 5 full builds of used powder, with automatic powder transport to the Mix Kit.

5. Finish

Clean and Polish with Fuse Blast: New 400 mm Fuse Blast Large Tumbler Basket fits 2-3× Fuse build volumes and 50% more parts per cycle. Optional Polishing System upgrade delivers smooth, semi-gloss, dye- ready surfaces.

Introduction to the Fuse Printing Ecosystem

Print with Formlabs Full Range of Materials

SLS

Nylon 12 White

Nylon 12 White Powder combines all of the great qualities of the general purpose and biocompatible Nylon 12 Powder with the customizability of white parts. Create functional prototypes and end-use customer-facing parts that can be easily dyed to match brand aesthetics as well as medical devices and models with high contrast and detail.

SLS

Nylon 12 Tough

Nylon 12 Tough Powder offers the best-in-class refresh rate among Nylon powders, high ductility, and great dimensional accuracy across the build chamber. Print more durable parts for prototyping and small batch production that have reduced warpage without sacrificing strength.

SLS

Nylon 12

Nylon 12 Powder is a general purpose, versatile, and biocompatible material with high detail and great dimensional accuracy. As the go-to material for SLS 3D printing, it is ideal for both functional prototyping and end-use production of complex assemblies and durable parts with high environmental stability.

Print with Formlabs Full Range of SLS Materials

SLS

Nylon 12 White

Nylon 12 White Powder combines all of the great qualities of the general purpose and biocompatible Nylon 12 Powder with the customizability of white parts. Create functional prototypes and end-use customer-facing parts that can be easily dyed to match brand aesthetics as well as medical devices and models with high contrast and detail.
SLS

Nylon 12 Tough

Nylon 12 Tough Powder offers the best-in-class refresh rate among Nylon powders, high ductility, and great dimensional accuracy across the build chamber. Print more durable parts for prototyping and small batch production that have reduced warpage without sacrificing strength.
SLS

Nylon 12

Nylon 12 Powder is a general purpose, versatile, and biocompatible material with high detail and great dimensional accuracy. As the go-to material for SLS 3D printing, it is ideal for both functional prototyping and end-use production of complex assemblies and durable parts with high environmental stability.

Real World Use Cases and Results

Brose: Leverages SLA and SLS
Technology
Rent the Sky Films: Camera Cable Harness

Functional Prototyping and End of Use Printing

Brose: Leverages SLA and SLS
Technology

Brose’s steady growth and their long-term successful partnerships with these OEMs are due in part to the company’s commitment to continuous innovation and improvement. 3D printing is at the core of multiple initiatives in Brose’s design and end-use manufacturing processes and has helped Brose adapt and respond to all the changes in the fast-paced automotive industry.

Results

  • Cost-Effective, On-Demand Manufacturing by reducing excess inventory and waste.
  • Bridged production gaps while waiting for traditional tooling, ensuring continuous workflow without delays

Ease in Automation

Rent the Sky Films: Camera Cable Harness

They print custom cable adapters for a 15 lb, handheld 3D camera that replaces conventional 100 lb rigs. These adapters consolidate cabling to a single interface point, making the camera simpler and easier to operate. Rent the Sky Films founder Scott Ferril describes this part as “the difference between getting the shots you want vs. the shots you have time for.”
Discover how 3D printing can streamline your operations—connect with us today to learn more.

Results

  • Reduced Cost - 16x cheaper
  • Reduced Production Time - 15x faster
  • 3 times lighter than the machined part replaced

Why Choose Markforged FX20?

Massive Builds, Faster

FX20 pairs size and throughput to make large parts at
incredible speeds. The FX20 build chamber is 84L —
nearly 5x larger than the Markforged X7. Its completely
redesigned motion and extrusion systems enable
high-speed printing without sacrificing quality.

Production-Ready

FX20 is a precise, sensor-driven machine that delivers
breakthrough reliability with a simple user experience.
Fully integrated storage and handling ensures materials
stay dry for printing, while sensors measure each part
of the extrusion system.

From Factory to Perfection

The FX20 extends The Digital Forge’s benefits to new industries, producing tooling, fixtures, and flight-ready parts. It also reinforces high-temperature plastics with CFR technology, bringing high-strength
3D printed composites to even more demanding
applications.

Print with Markforged's Full Range of Composite Base Materials and Continuous Fibers

Compatible Materials
Onyx®
Vega™
ULTEM™ 9085 Filament
Onyx FR™
Carbon Fiber
Carbon Fiber FR
‍
Vega is Markforged’s first engineered high temperature plastic — an ultra high-performance carbon fiber filled PEKK for 3D printing critical aerospace parts. Vega can be reinforced with continuous fiber to achieve aluminum strength for replacing structural, non-critical aerospace components. It exhibits a smooth black matte surface finish that is excellent for production parts with minimal post processing.
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