First feedback on the Fuse1+30W

I would like to give our first impressions of the Fuse1+30W, which we put into operation 4 days ago.
Some posts by the user @LEADNAV gave us first insights into the device before we bought it. I would like to do the same here for forum members and interested parties.
Since the first posts were about specific problems, I wanted to open a new one on this topic.

So far, we have almost no complaints about the Fuse1+30W.

The installation was supposed to be done by a technician on site, but since we ordered at short notice before the Christmas holidays, the installation was only possible by video call this year.
We bought from a dealer in Germany and both the remote installation and support questions have been absolutely no problem so far. Our dealer already had experience with this type of installation and within an approx. 5 hour call on the first day and another approx. 1 hour call on the second day, all devices were set up, the first print job printed and post-processed and all initial questions answered.

As this is our first SLS device, we opted for a Starter Bundle, which includes all accessories in addition to the devices, as well as the Premium Services. So far, I would do this again.

For the time being, we are only using the PA12 powder, as we consider this to be sufficient for the time being. If not, it should be relatively easy to switch to PA12GF, as it is the same polymer base. Even though with the Fuse1+ we have the possibility to print under protective gas atmosphere for PA11CF, we hope that the other materials will be sufficient.
The decision to use the Fuse1+ instead of the Fuse1 is largely based on the higher printing speed and minor improvements within the printer. These are for example (according to our dealer) an improved material dosing system and a better spindle in the powder hopper which makes clumping less likely.

In the first four print jobs so far, there have been absolutely no problems and the results have been impeccable, with one minor exception.
The print quality is indeed absolutely impressive, although additional sanding is absolutely necessary. In my opinion, it is somewhat strange why Formlabs only recommends it, but does not offer it with a device itself. Since it fits in well with the rest of the ecosystem, we decided to start with the 2021 sandblasting cabin from Sinterit.
Already on the second print job, we tried to test the limits of the Fuse1+ and printed a possibly familiar figure. Here, the individual parts were printed and then assembled. The tolerances are a little too loose on the arms so that they fall out quite easily, but it shows the possibility of the printer.

What we have noticed so far during installation and working with the Fuse1+ is that some of the instructions and illustrations on the display are still based on the Fuse1. Since there are very slight construction differences between the machines, one or two things do not quite fit. You can still find your way around the pictures, but some points will have to be adjusted.

One small thing that we had to pass on to support for the time being is a problem with the light in the Fuse Sift. It does not work. But this is not a problem for the time being and I’m not worried that the support team won’t be able to help us.

So far, the devices have proven to be absolutely reliable with an industrial quality.
For questions or exchange needs, please ask below.

Fuse1+ Figure - YouTube


Congrats on the new machine.

I can maybe cover our post processing methods as they are pretty dialed in… we blast cabinet the parts with fine glass bead then we purchased an actual “Sous Vide Cooker” to steam bath the parts in Rit Dye (Graphite…we felt the Black was a little too harsh and “fake” looking).

This cooker has worked outstanding as it holds the dye mix till we’re ready to heat it up and soak. I brain stormed this idea to use a Sous Vide when I was pricing out the ridiculously priced “Dye tanks” for additive.

Here is the one we use.

We pile parts on the rack, drop it in for 25 minutes at max temp, then rinse well then compressor blow off the parts to minimize any left over dye and streaking. We then put em on a tray with a small fan to air dry them prior to packaging.

As far as the Sift lighting…we had the same issue. One light bar “went out”. They sent us another but when I went to pull the top off the Sift, I found that the bulbs small JST connector had just come undone. I told Formlabs that a better connector would be advised for a machine that’s made to vibrate but so far it has not come undone again. I’m assuming yours came loose in shipping.

Side note…our first delivered Sift was a total lemon…mother board was bad…so they shipped another

My Fuse 1 is actually now down. I will update the thread I did last week on the surface warping on the new XY dimensional test print… but essentially we figured out that my heater bulbs were fried, oneside being completely black and the coils inside were damaged. So they are sending a new set $190 and a new IR temp sensor (cost unknown) to troubleshoot.

My parts went from being beautifully accurate dimensionally to all over the place and I noticed my surface armor was “different”. Harder to blast off. After a few failed chambers…now I know. Glance at your Heater Bulbs once in awhile. Hopefully it is just a bad IR Sensor and these parts get it running again, fingers crossed.

See thread "Rippling" and uneven top layer Finish / on XY calibration print - #2 by LEADNAV

Interested to see how the Fuse1+ does when you switch to 12GF!

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Thanks so much for sharing your experience with the Fuse 1+ so far! I love the LEGO print and might need to make a few of my own after seeing that, haha. Please do be sure to reach out to our Support Team with any questions or concerns (especially if you are not already in touch for the light issue) and we can do our best to assist. Take care!

Great review!
As You’ve explained everything here quite detailed, wanted to ask, hear your feedback about tolerances. Have You tried to produce series of parts in several batches? And have You faced any problems with tolerances?
We’re using Fuse1 with Nylon12 and I have some small parts with hole for D-shaft feature. And for the round segment there’s a +/-0.02mm diam. tolerance. In simpler words, You can consider there’s a D6.60 hole with tolerance +/-0.02mm. I understand that this is a small grade tolerance, but the issue I’m facing with here is that this dimension deviation isn’t systematic. In other words, some batches come with, for example, 95% success rate, but in other batch there’s suddenly more than 50% parts to scrap. The parts are oriented according to recommendations - hole axis align with Z-axis and all these kind of parts are placed together in several layers. And in chamber they’re also placed in same region.
So maybe someone can give feedback on similar cases and mention some influencing factors which would disturb this consistency?