Formlabs has introduced the Fuse X1, a large-format SLS (Selective Laser Sintering) 3D printer that aims to revolutionize the additive manufacturing landscape. The Fuse X1 ecosystem is designed to produce high-quality parts on the same day, at a 50% lower cost compared to existing systems, and achieve three times the throughput of its competitors. Priced starting at $84,999, the printer is available for pre-order with deliveries expected to begin in the fourth quarter of 2026.
The Fuse X1 was developed with the goal of making high-throughput additive manufacturing accessible to a wider range of users, including manufacturers, engineering teams, and service bureaus. Early access customers like Tesla and Radio Flyer have leveraged the Fuse X1 to accelerate product development and produce over 30,000 parts in just four months. Max Lobovsky, co-founder and CEO of Formlabs, emphasized that the Fuse X1 offers an industrial-scale SLS printing solution that does not require a significant initial investment or infrastructure.
The printer can fit through a standard door, be installed in roughly one hour, and operates on standard single-phase power without needing specialized HVAC systems. The Fuse X1 ecosystem consists of the printer itself, a modular Build Unit, the Fuse Sift X1 for powder recovery, a Vacuum Conveyor for automated powder transport, and a high-capacity configuration for media blasting and polishing.
Key specifications of the Fuse X1 include a build volume of 330 × 330 × 565 mm with over 30% packing density, making it capable of reducing part costs significantly when compared to traditional industrial SLS and MJF printers.
Additionally, the Fuse X1 incorporates new technologies, such as Adaptive Thermal Control and AI-Powered Print Intelligence. The Adaptive Thermal Control feature allows greater packing density while maintaining stable print conditions throughout the build chamber. It processes thermal data at a substantially higher rate than previous models, enabling precision during the sintering process. The AI-Powered Print Intelligence system monitors each layer using thermal imaging to identify defects in real time, helping to save materials and reduce waste.
Early users like Tesla and Radio Flyer have praised the Fuse X1 for enhancing efficiency in their production processes, with Tesla noting that it has transformed their project management capabilities. Radio Flyer remarked on the drastic reduction in prototype lead times for their e-bike frames, going from two months to just a few days.
The Fuse X1 will be publicly showcased for the first time at the Reindustrialize Summit in Detroit on June 16, 2026, and parts are available for order through Formlabs’ new online 3D printing service.