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Formlabs Fuse Blast Reinvents SLS Post-Processing, Taking Parts From Printed to Finished in 15 Minutes

10 Nov 2023  

Formlabs Fuse Blast Reinvents SLS Post-Processing, Taking Parts From Printed to Finished in 15 Minutes

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The Fuse Blast, a fully automated SLS post-processing solution, completes the Formlabs Fuse Series ecosystem, and a range of software improvements enable faster job setup, printing, and pre- and post-processing.

At Formnext, Formlabs, the leading 3D printing company, announced it is reinventing post-processing for SLS 3D printing with the launch of Fuse Blast, a fully automated part cleaning and polishing solution. As the newest addition to the Formlabs SLS printing ecosystem, the Fuse Blast drastically lowers labor and overhead costs, reduces post-processing time by 80%, and delivers consistent, customer-grade parts in as little as 15 minutes. Formlabs leads the SLS 3D printing industry, with Fuse 1 Series printers accounting for nearly half of the world-wide powder bed fusion printers sold since the Fuse 1 launched in 2020. Expanding the SLS ecosystem with the Fuse Blast and new software updates will support the fleet of Fuse printers on the market that are used across automotive, manufacturing, engineering, and other fields. 

Providing cleaning and surfacing within one system, the Fuse Blast features automatic tumbling for completely hands-off cleaning that quickly removes semi-sintered and loose powder, as well as an in-line ionizer that prevents dust from re-settling on parts to ensure parts are always clean-to-the-touch. Enabling decreased overhead costs and faster production, the Fuse Blast will simplify, improve, and streamline post-processing with:

  • Pre-Programmed Routines: Pre-programmed settings, compatible with multi-material cycles, are included to eliminate guesswork and deliver consistent results. While most parts can be cleaned with the Standard setting, users can also use the Nylon 12GF Powder setting to get rid of strong surface armor, and Delicate, for a more gentle tumble cycle.
  • Manual Assisted and Hand-Held Cleaning Options: Users can choose the ergonomic manual assisted cleaning option for larger parts while holding it with both hands, or the manual hand-held cleaning option to easily clean intricate features that require line of sight with precision. 
  • Fuse Blast Polishing System: This upgrade goes beyond cleaning to surface finishing, delivering clean parts that are also smooth, scuff-resistant, and dye-ready with a professional semi-gloss finish. 

"The Fuse Blast is a huge step forward for the Formlabs SLS ecosystem, bringing the same ease-of-use and accessibility that we are known for in the SLA space by enabling users to get clean-to-the-touch, industrial-grade SLS parts in as little as 15 minutes after printing,” said Dávid Lakatos, Chief Product Officer at Formlabs. “Combined with our newest software updates, we're continuing to streamline the SLS 3D printing process so Formlabs users can print high-quality parts faster." 

Early Fuse Blast users have already seen firsthand how it streamlines their post-production workflows and helps them get industrial-grade parts in record time. “Adding this system to any new or existing SLS workflow is a massive improvement over a manual cleaning and post-processing workflow,” said Chris Haak, Operations Lead at Autotiv, a contract manufacturer with customers in industries like robotics, automotive, consumer goods, and more. “The Blast also takes stress off of our bodies due to removing the repetitive movement of manual cleaning.”

The Fuse Blast will begin shipping in early 2024, and the Fuse Blast Polishing System will be available globally in H1 2024. In addition, Formlabs shipped a major software update to all of its existing Fuse Series Printers to enhance capabilities and make it a more powerful system than ever, with faster job setup, printing, and pre- and post-processing workstreams. New Fuse software updates now available include:

  • 30% increase in print speeds for Nylon 12 Powder on Fuse 1+ 30W printers
  • Improved packing algorithm for better packing density, reducing powder waste by 42% on average
  • Better part resolution for Nylon 12 Powder on the Fuse 1+ 30W enabling strong and fully resolved fine features to create thin walls, pins, struts, and embossed text

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