Formlabs Fuse 1
Safety
While the Fuse 1 is a very safe machine, there are a few things to be aware of when using this equipment.
The build chamber usually takes a number of hours to cool down after a print, so do not attempt to remove it during that time.
When removing the parts from the powder after the print, certain PPE is required.
You must wear an N95 mask when handling unsintered powder.
Gloves are recommended but not required when the powder is at room temperature.
Safety glasses are recommended while handling unsintered powder.
While cleaning the powder off of parts after a print, keep anything that could cause a spark away from the general area of the Fuse sift.
Rules
You may clean your own parts in the Fuse Sift, but the build chamber must be moved over by a staff member.
This printer will not be used for printing a single part, unless that part is designed in such a way that it will not waste much powder.
If you have only one part, staff members can add more parts to the print job.
We will only be using the Nylon 12 material because it is very difficult to change powders.
HOW DO I GET ACCESS TO THESE PRINTERS
The Fuse 1 is a higher end printer with more intricacies than the Ultimakers and therefore requires training. You must first have printed several times with the Ultimakers before moving to the Fuse 1 printer. To complete the training, prepare a print file according to the First Print guide with any part you want and then demonstrate to a staff member your sliced file and proper procedures for starting and finishing a print.
How does it work?
The Formlabs Fuse 1 printer uses Selective Laser Sintering (SLS) technology to build parts out of powdered nylon. The way this technology works is that it lays down a thin layer of powder, sinters (solidifies) it in the desired locations using a laser, and repeats with the next layer. Because your part is always sitting on powder you do not need any supports. However, you can never print a hollow sphere because there will be no way for the powder to be removed from the inside of the sphere.
With this printer more parts and less height is better because it will have to fill the entire bed with powder up to the height of your tallest print. Any unsintered loose powder after the print will have to be removed and although it can be recycled (at a 70% refresh rate) it is less efficient to have lots of unnecessary loose powder.
The Fuse Sift (on the right) is used for cleaning the powder off of the parts and for recycling it.
MATERIAL COSTS
The material for the Fuse 1 is $0.05/gram and any print must have a minimum packing density of 15%.
If you are having trouble getting the packing density to that point, please talk to a staff member.
You are permitted one free print up to 200 grams every two weeks but it must have a minimum of 20% packing density.
If you are having trouble getting the packing density to that point, please talk to a staff member.
Always refer to the Material Store page for the most updated pricing.
This print is 490 grams of fused powder and has a packing density of 28%. It will cost $24.50.
More resources
Learn how to make your first powder print on the Fuse 1!
Materials & Applications
We have Nylon 12 powder available currently for use with the Fuse 1
Nylon 12 is great for functional prototyping and end-use parts that need durability. The parts can have slight flexibility but it's dependent on how the part is modeled - like a spring
Applications:
Functional prototyping
End use parts
Jigs, fixtures
Etc...
Not ideal for powder printing
Parts with small thin features
Parts that can be printed on the Ultimakers
Part has no need for durability
Jigs, fixtures
Etc...