It’s really strange how many problems some people seem to have with their fuse. This year we were back at Formnext in Frankfurt, Germany, one of the largest trade fairs for additive manufacturing, and spoke to our dealer who looks after Formlabs customers. As we have been a customer here for a long time, we buy all our material, spare parts and maintenance from this dealer and not from Formlabs directly. This has nothing to do with a dislike of Formlabs - after all, we use their printers and materials - but we simply try to have as few purchasing sources as possible.
Again, the internal feedback we have received is that most customers work very well with their Fuse printers, but there are a few who just seem to have one problem after another.
So far we have only had 2 failures in the 2 years we have had our Fuse1+. Once a temperature sensor failed, which had to be replaced. Here we still had a service plan, so a technician was sent by our dealer.
Then we had the problem with the dents in our parts. We described this in this post:
Replacement Fuse 1 not working - PART 2 - Support & Troubleshooting / Fuse 1 - Formlabs Community Forum
I have the impression that our bumps were at the same height as the problem images shown.
In our case, it turned out that we had the faulty print beds.
Two new ones were sent to us. I changed one myself and saved one and had the technician change it again when he was on site for the annual service. In this way, I wanted to test whether the installation might cause errors with the print chamber. Both chambers have been working without any problems since then.
We don’t print very often with our Fuse1+. On average it is 1 print job per week. This often includes express jobs where the chamber is only a quarter full. We then print several small parts exactly in the problem area shown, currently without any problems.
Our Fuse currently has a success rate of over 95%.
I can therefore at least not support the design error mentioned. Not much help at this point, I know, sorry.