Today, Formlabs announced a new large-format SLS ecosystem, delivering production-quality parts the same day at up to 50% lower cost and three times the throughput of competing systems. The Fuse X1 ecosystem is available starting at $84,999 and open for orders with deliveries beginning in Q4 2026. This selective laser sintering system is aimed at making high-throughput additive manufacturing more accessible to manufacturers, engineering teams, product developers, and service bureaus.
Formlabs also reported that early access customers in automotive and consumer products—among them Tesla, Radio Flyer, and Autotiv Manufacturing—have used the Fuse X1 to accelerate development and scale production, printing more than 30,000 parts in four months. The system is positioned to enable reliable, scalable decentralized manufacturing at a lower price point than comparable industrial solutions.
“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 mass manufacturing. Customers no longer need to spend half a million dollars or dedicate an entire facility to manufacturing production-grade parts quickly and reliably.”
Although a large-format system, the Fuse X1 ecosystem is designed to fit through a standard door, install in about an hour, and run on standard single-phase power without specialized HVAC. The ecosystem includes the Fuse X1 printer and modular Build Unit, the Fuse Sift X1 powder recovery station, the Fuse X1 Vacuum Conveyor for automated powder transport, and a high-capacity configuration of the Fuse Blast system for media blasting and polishing. Key specifications and capabilities include:
- 330 × 330 × 565 mm build volume with a packing density above 30%
- Up to 50% lower part cost compared with legacy industrial SLS and MJF systems
- Footprint of less than half the floor space of legacy industrial SLS and MJF systems
- Same-day production of large parts and up to three times the throughput of competitors
What’s New about the Fuse X1: Adaptive Thermal Control, AI-Powered Print Intelligence
Two notable features introduced with the Fuse X1 are Adaptive Thermal Control and AI-powered Print Intelligence. Adaptive Thermal Control enables greater packing freedom in large-format SLS by using a thermal architecture that preserves stable print conditions across the entire build chamber. Formlabs states the system collects and processes far more thermal data per second than previous systems and uses 13 independent thermal zones to maintain precise and stable temperatures throughout the print. Where typical MJF printers recommend packing densities around 10–15% by volume, the Fuse X1 can exceed 30% packing density, allowing significantly more parts per build and boosting throughput.
Print Intelligence refers to an AI-driven failure prevention suite that combines computer vision and thermal imaging to monitor each layer and detect anomalies before a build is compromised. When defects are detected, the system can selectively exclude affected parts from subsequent layers, conserving material and reducing wasted print time.
Which Companies Have Already Used the Fuse X1?
Formlabs reports that several early access customers are already leveraging Fuse X1 for development and production. Tesla is using the system to accelerate product development and produce end-use parts and tooling for manufacturing. “With the increased throughput and decreased costs, Fuse X1 has completely changed our perspective on what kinds of projects our lab can support versus what we would have traditionally moved to an injection mold,” said Cody Jepson, Engineering Technician, Additive Manufacturing at Tesla Giga NV.
Radio Flyer used the Fuse X1 to shorten prototype lead times for its Flyer Loop cargo e-bike frame. “With Fuse X1, we can now print an entire Flyer Loop cargo e-bike overnight and be gluing it together the next day. So we went from two months to two weeks to a couple of days. I can iterate three times as often with nine times less labor,” said Agostino LoBello, Product Development Engineer at Radio Flyer.
Fuse X1 parts will be available to order for customers in the US through Formlabs’ online 3D printing service, Form Now. The Fuse X1 will be showcased publicly at the Reindustrialize Summit on June 16 in Detroit, MI.
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*Cover Photo Credits: Formlabs