Formlabs unveils industrial printer with higher throughput

Formlabs, a U.S.-based manufacturer of 3D printers, has launched sales of the Fuse 1+ 30W, a new industrial selective laser sintering (SLS) printer.

The printer is Formlabs’ follow-up to the Fuse 1 SLS printer, which was the company’s first industrial SLS printer. The Fuse 1+ 30W integrates upgraded components, including a more powerful 30-watt laser with an improved galvanometer system that can produce parts up to twice as fast, according to the company. It is capable of rapid scanning speed of up to 12.5 meters per second, with parts delivered in-house in less than 24 hours.

The company presented an example on its website of a bicycle seat that took 18 hours and 22 minutes to produce on the Fuse 1 printer using Nylon 12 Powder. The same seat, on the new Fuse 1+ 30W printer took 14 hours and one minute to produce, representing a 24 percent time savings. A second example, involving a shaft coupling, showed a reduction in print time from 66 hours and 19 minutes to 32 hours and 59 minutes, which is a 52.2 percent reduction in print time.

The original Fuse 1 SLS printer uses a 10-watt laser.

The new printer features low-waste printing due to an improved powder handling system, high packing density, and powder recyclability, resulting in low-cost part production and a fast return on investment, according to the company.

A new agitator within the powder hopper creates a consistent, smooth delivery of material into the build chamber.

A new optional nitrogen supply feature creates an inert gas environment during the print process, eliminating unwanted oxygen from the sintering environment. When printed in this inert environment, parts display less brittleness and better ductility. These characteristics can be important in end-use components, especially for the automotive or aerospace industries. Compatible nitrogen generators are widely available for purchase, and Formlabs representatives can recommend specific models.

The Fuse 1+ 30W upgraded components will allow it to work with new high-performance materials. In conjunction with the new printer’s release, Formlabs released Nylon 11 CF powder, a nylon-based, carbon-fiber-reinforced powder material that allows users to print strong, stiff, lightweight parts with dimensional stability and thermal stability. The powder can produce rigid parts that can withstand repeated impact, making it an ideal material for replacing metal parts, according to the company. It represents Formlabs’ first carbon-filled material.

The controlled atmosphere also enables a more efficient sintering process for Nylon 11 powder and the new Nylon 11 CF powder by better preserving unsintered powder from oxidation, allowing more of it to be reused in the next printing cycle, which increases the powders’ recyclability.

“With the Fuse 1+ 30W, we’re pushing SLS 3D printing to new heights — delivering truly rapid, high-throughput SLS printing at a price point companies can afford,” Max Lobovsky, Formlabs co-founder and CEO, said in a statement.

Formlabs is selling the Fuse 1+ 30W for $27,999 on its website. The original Fuse 1 SLS printer is selling for $18,999. It is marketing the printers to a variety of industries ranging from engineering and manufacturing to dental and health care.

The Fuse 1+ 30W’s affordable entry price will allow small to medium-sized manufacturers to not only bring SLS in-house, but scale up production, the company said. Low cost-per-part production, faster turnaround time and streamlined workflow can also reduce overall manufacturing costs, according to a Formlabs statement.

Contact:

Formlabs Inc., Somerville, Mass., 617-702-8476, www.formlabs.com

 Bruce Geiselman

[email protected]