Formlabs today announced the launch of the Fuse X1, an industrial large-format selective laser sintering (SLS) 3D printing ecosystem aimed at making high-throughput additive manufacturing more accessible to manufacturers, engineering teams, product developers, and service bureaus.
The company stated that early access customers, including Tesla, Radio Flyer, and Autotiv Manufacturing, have used the Fuse X1 to accelerate product development and scale production, printing more than 30,000 parts within a few months. According to Formlabs, the new system is designed to enable reliable and scalable decentralized manufacturing while reducing costs across a range of applications, including drone manufacturing.
“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.”
Starting at $84,999, Fuse X1 delivers production-quality parts in under 24 hours with up to 50% lower cost per part and 3 times the throughput of comparable industrial powder bed fusion systems. The ecosystem combines large-format printing, AI-powered reliability features, automated powder handling, and an intuitive workflow in a compact system that fits through a standard door, installs in approximately one hour, and operates on standard single-phase power without specialized HVAC requirements.
Key specifications and capabilities include:
- 330 × 330 × 565 mm build volume, with 30%+ packing density
- 50% lower part cost versus legacy industrial SLS and MJF printers
- Less than half the floor space versus legacy industrial SLS and MJF printers
- Same day large parts and 3x the throughput of competitors
- AI-powered Print Intelligence failure prevention
- One-hour installation, five-minute print changeovers, intuitive workflow requiring no dedicated operators
Industrial SLS Reinvented: Adaptive Thermal Control and AI-Powered Print Intelligence
With Fuse X1, Formlabs is also introducing Adaptive Thermal Control and AI-Powered Print Intelligence, two first-of-their-kind SLS technologies.
Adaptive Thermal Control unlocks unlimited packing freedom in large-format SLS for the first time with a new thermal architecture designed to maintain stable print conditions across the build chamber. It collects and processes 700 times more thermal data per second than the Fuse 1+ 30W, driving 13 independent thermal zones that deliver, maintain, and sinter powder at an incredibly precise and stable temperature from the first layer to the last, giving customers unlimited freedom and exceptional part quality.
While the maximum recommended packing density for MJF 3D printers is approximately 10-15%, Fuse X1 can achieve over 30% volume packing density to fit more parts per build and achieve unprecedented throughput.
Print Intelligence is an AI-powered failure prevention system that uses computer vision to monitor every layer with real-time thermal imaging to detect anomalies before your build fails. Print Intelligence™ detects part defects in real time and selectively removes the affected part from the following layers, saving materials and time.
The Fuse X1 ecosystem includes the Fuse X1 printer and modular Build Unit, Fuse Sift X1 for powder recovery, Fuse X1 Vacuum Conveyor for automated powder transport, and a new high-capacity configuration for Fuse Blast for media blasting and polishing.
Customer Validation Across Manufacturing and Product Development
Early access customers have already used Fuse X1 to accelerate product development and scale production.
Tesla has adopted the Fuse X1 to accelerate product development and to produce end-use parts and tooling for its manufacturing line, benefiting from the printer’s sheer build volume and throughput. “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.” Cody Jepson, Engineering Technician, Additive Manufacturing at Tesla Giga NV
Radio Flyer, the iconic American toy and electric bike brand, cut prototype lead times for its Flyer Loop cargo ebike frame. “With Fuse X1, we can now print an entire Flyer Loop cargo ebike 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.
Autotiv Manufacturing, which operates more than 200 printers and delivers 10,000 printed parts across the country each week, expects to achieve a return on investment five times faster than comparable SLS systems. “Thanks to about half the upfront cost and about double the throughput, you can get a return on investment extremely quickly,” said Evan LaBelle, CEO of Autotiv.
In the four months prior to the announcement, Formlabs customers printed over 30,000 parts on Fuse X1 units. Fuse X1 parts will also be available for order for customers in the US starting today on Formlabs’ new online 3D printing service, Form Now. Fuse X1 will be first showcased in public at the Reindustrialize Summit on June 16th in Detroit, MI.
Company Momentum
Formlabs also shared some key financial results for the first time and company milestones, highlighting its growth and adoption across the additive manufacturing industry.
- Largest professional 3D printing company founded since the 1980s
- Annual revenue surpassing $250 million in 2025
- Greater than 10% free cash flow margin while maintaining profitability for over 2 years
- More than 500 million parts printed by customers using Formlabs printers and materials
- Net Promoter Score (NPS) of 60 for Form 4 and Form 4L, reflecting strong customer satisfaction
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