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. The system enables reliable, decentralized manufacturing while reducing production costs across a wide range of applications.

“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 ecosystem combines large-format printing, AI-powered reliability features, automated powder handling, and an intuitive workflow in a compact system that fits through a standard doorway, installs in about an hour, and runs 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

Formlabs is also introducing two new technologies with Fuse X1: Adaptive Thermal Control and AI-Powered Print Intelligence.

Adaptive Thermal Control uses a new thermal architecture that processes 700 times more thermal data per second than the Fuse 1+ 30W and manages 13 independent thermal zones across the build chamber. This enables stable print conditions, exceptional part quality, and greater freedom in part placement and packing. While typical MJF systems are recommended for packing densities of around 10–15%, Fuse X1 can exceed 30%, allowing more parts per build and significantly higher throughput.

Print Intelligence uses computer vision and real-time thermal imaging to monitor every layer during printing. The system detects anomalies and defects as they occur and can selectively remove affected parts from subsequent layers, reducing material waste and preventing full-build failures.

The Fuse X1 ecosystem includes the Fuse X1 printer and modular 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 media blasting and polishing.

Early access customers have already demonstrated the platform’s impact. Tesla is using Fuse X1 to accelerate product development and produce end-use parts and tooling, benefiting from its large build volume and throughput. Radio Flyer significantly reduced prototype lead times for its Flyer Loop cargo ebike, enabling complete frame prototypes to be produced overnight and shortening development cycles from months to days. Autotiv Manufacturing expects to achieve a return on investment up to five times faster than with comparable SLS systems due to lower upfront costs and increased throughput.

In the four months prior to launch, Formlabs customers printed more than 30,000 parts on Fuse X1 systems. Beginning today, 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