Selective Laser Sintering (SLS) 3D printers operate based on a consistent process, yet they vary significantly in aspects like laser type, build volume dimensions, and system sophistication. Temperature regulation, powder distribution mechanisms, and layer deposition techniques are also key differentiating factors among various machines.
Maintaining precise temperature control is crucial in selective laser sintering. Throughout the preheating, sintering, and post-printing cooling phases, the powder bed and partially formed parts must be kept within a 2 °C temperature range. This stringent control minimizes issues such as warping, internal stresses, and heat-induced distortions in the final product.
Traditional Industrial SLS 3D Printers
For decades, selective laser sintering has remained a favored 3D printing technology among professionals. However, its inherent complexity, stringent operational requirements, and substantial cost have primarily restricted its adoption to specialized service bureaus and large-scale enterprises.
These industrial-grade machines necessitate dedicated HVAC systems and industrial-level power supplies. Even the most compact industrial Sls Printer models occupy a considerable installation space, often around 10 square meters. Setting up these systems is a complex undertaking, typically spanning several days and requiring on-site installation and specialized training. Furthermore, the intricate workflow and steep learning curve associated with traditional industrial SLS printers necessitate the presence of a highly skilled in-house technician for operation and ongoing maintenance.
With entry-level prices starting at approximately $200,000 and escalating rapidly for comprehensive setups, traditional industrial SLS printers have remained financially out of reach for many businesses.
Fuse Series: Pioneering Benchtop Industrial SLS 3D Printers
Similar to trends observed in other 3D printing technologies like Fused Deposition Modeling (FDM) and Stereolithography (SLA), the SLS market has recently witnessed the emergence of more affordable and compact systems. Early iterations of these lower-cost SLS solutions often involved compromises, such as reduced part quality and complicated, manual workflows, particularly due to the absence of effective post-processing solutions. These limitations hindered their applicability in demanding industrial and production environments.
The introduction of the Formlabs Fuse 1 marked a turning point, establishing a new category of benchtop industrial SLS 3D printers. The Fuse 1 delivered industrial-quality parts within a compact footprint and streamlined workflow, all at a significantly lower cost compared to traditional industrial SLS systems. The subsequent generation, Fuse 1+ 30W, further advanced this category with a more powerful laser, enhanced powder handling capabilities, and expanded material compatibility, enabling higher throughput and industrial-grade part production.
The Fuse Series ecosystem is designed for easy integration into standard workspaces, eliminating the need for specialized infrastructure.
Fuse Series SLS 3D printers, such as the Fuse Series SLS 3D printers, utilize a single laser and a smaller build chamber, requiring less energy for heating. Their lower energy consumption means they can operate on standard AC power, negating the need for specialized electrical infrastructure. The optional nitrogen environment feature available for the Fuse 1+ 30W enhances the quality of unsintered powder by creating an inert atmosphere. This preservation allows for a lower refresh rate (higher ratio of recycled to new powder in successive builds), reduces material waste, and improves the surface finish of sintered parts.
Fuse Series printers also incorporate a patented technology known as Surface Armor. This semi-sintered shell maintains consistent heating around the parts during printing, resulting in superior surface finishes, reliable mechanical properties, high print reliability, and improved refresh rates.
Completing the compact and self-contained ecosystem, Fuse Series printers are complemented by Fuse Sift, a versatile device that integrates part extraction, powder recovery, storage, and mixing, and Fuse Blast, a fully automated solution for cleaning and polishing printed parts.
Benchtop industrial SLS 3D printing, exemplified by the Fuse Series, offers a slightly reduced build volume compared to entry-level traditional SLS systems. However, this is offset by a significantly smaller machine footprint, a simplified workflow, and a lower overall cost of ownership.
Resources
SLS for End-Use Production
The Fuse SLS Ecosystem makes 3D printing for end-use production more accessible, adaptable, and scalable than ever before. Explore comparisons of production methodologies, bulk powder pricing, and real-world production examples from 15 manufacturers currently utilizing the Fuse Series.
White Paper
3D Printing Industry: Formlabs Fuse 1 & Sift In-Depth Review
Access an in-depth engineer’s report by 3D Printing Industry, featuring a comprehensive review of Formlabs’ SLS 3D printers and detailed accuracy testing outcomes.
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Comparing SLS 3D Printers
| Feature | Fuse Series: Benchtop Industrial SLS 3D Printers | Traditional Industrial SLS 3D Printers |
|---|---|---|
| Price | Starting just under $30,000 for the printer and $60,000 for the entire ecosystem | $200,000-$500,000+ |
| Print Volume | 165 x 165 x 300 mm | Up to 550 x 550 x 750 mm |
| Pros | Affordable, High-quality parts, High throughput, Multiple material options, Simplified workflow, Small footprint, Low maintenance | Large build volume, High-quality parts, High throughput, Multiple material options |
| Cons | Smaller build volume | Expensive machinery, Large footprint, Facility requirements, High maintenance, Requires a dedicated operator |
Comparison based on Formlabs Fuse Series benchtop industrial SLS system and traditional industrial SLS systems by EOS and 3D Systems.
White Paper
Outsourcing vs. In-House: When Does it Make Sense to Bring SLS 3D Printing In-House?
This white paper evaluates the value proposition of integrating SLS 3D printers in-house compared to outsourcing SLS part production from service bureaus.
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White Paper
Fuse Series SLS Printers vs. Traditional Powder Bed Fusion Systems
This comparative guide outlines the primary distinctions between compact SLS printers like the Formlabs Fuse Series and traditional large-footprint machines.
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