This is a follow up report on all the issues we’ve had with Formlabs and the Fuse 1 system as a whole. You can go read them all and particularly the FUSE 1 IS DEAD thread before this but essentially…we are still down without a Formlabs system that will work.
After all the issues we had and the last Fuse 1, Sift and chamber being faulty, in which we were told is extremely rare and never happens, we were finally “allowed” to pay another $12k to get a Fuse 1+ 30 as a replacement to the faulty Fuse 1 we’ve been dealing with.
It arrived last week and it has not run anything as it is showing the same problems. I assumed this was to do with the original two chambers we had getting screwed up when the first Fuse 1 cooked itself after the December Firmware update but in the past week, I have swapped gaskets with no luck and last night I fully disassembled the Chamber bed on one unit and did maintenance on the fiber gasket and metal mesh tube buffer around the edges till I thought I had a pretty good mechanically operating chamber. Ran another print and the same failures with cracking along the edge of chamber in the initial powder prime and preheating.
NOTE: These two $3500 (each) chambers I’m fully dissembling (they sent me the service manual for them too) have less than two dozen print jobs on them…and here I am pulling them apart to troubleshoot them.
They are sending an entirely new chamber to cancel that out but as of this morning and my multiple photos and videos of the failures…they are now also sending me a “dozer assembly and expecting me to fully disassemble the brand new Fuse 1+ to replace this dozer as a possible issue”…
I am a little lost for words at the moment and extremely irritated as if they truly think this is now a dozer issue on a second brand new machine…well then I guess I am unlucky as this supposedly “never happens”. I’m also tired of just being expected to install new parts myself to get this new unit running.
I am more irritated that no one at Formlabs can finally get me a running system as I was sold on full support in keeping this thing going and not yet to have a single voice call, zoom call or even the in person service I was expected to receive.
I know additive is a new thing…new companies…but this is not how you survive in the manufacturing world. If this was any of our CNC machine companies handling business this way…they would be done. Our friends in the manufacturing and sales markets are in shock at our experiences so far and the handling of this situation. I did not plan on getting qualified as a full service and repair rep for Formlabs when investing in this system…I already wear enough hats.
If I did not have this system running successfully for a few months prior to their firmware update, I wouldn’t even believe this system actually works and would have given up on it entirely. I’m about at that point, as I am getting past the point where any return on investment would/will be possible as a viable business option for production parts.
Go ahead and look at what they are expecting me to do…to this brand new replacement $30k printer I just received last week and dropped another $12k on over the first lemon…and tell me what you think…
Replacing Dozer assembly
Here is what is still happening and failing prints
Scraped away the powder to show where the cracks are forming over the chamber wall. I still think this is a heating issue in the chamber walls translating up through the powder and cracking it… but it seems were all guessing at this point.