Formlabs Unveils Fuse X1: Industrial Large-Format SLS 3D Printing at a Fraction of the Cost

Fuse X1 delivers production-quality parts in under 24 hours, with up to 50% lower cost and 3× higher throughput than comparable systems.

Formlabs, the world’s largest supplier of professional SLA and SLS 3D printing systems, has introduced the Fuse X1, a large-format industrial 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 printed more than 30,000 parts using Fuse X1, accelerating product development, scaling production, and reducing manufacturing costs.

Starting at $84,999, Fuse X1 produces production-quality parts in under 24 hours, delivering 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, automated powder handling, AI-powered reliability features, and an intuitive workflow in a compact system that fits through a standard doorway and installs in about an hour.

Key specifications include a 330 × 330 × 565 mm build volume, packing densities exceeding 30%, same-day production of large parts, AI-powered failure prevention, and reduced floor-space requirements compared with traditional industrial systems.

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, enabling stable print conditions, improved part quality, and higher packing density. Print Intelligence uses computer vision and real-time thermal imaging to detect defects during printing, helping reduce material waste and prevent full-build failures.

The complete ecosystem includes the Fuse X1 printer, Fuse Sift X1, an automated Vacuum Conveyor, and a high-capacity Fuse Blast finishing solution. Fuse X1 will make its public debut at the Reindustrialize Summit in Detroit on June 16.