en.Wedoany.com Reported - Formlabs has launched the Fuse X1, a large-format Selective Laser Sintering (SLS) 3D printing system, with a starting price of $84,999, and has publicly disclosed its financial performance for the first time. The company reported revenue exceeding $250 million in 2025, with a free cash flow margin of over 10%, and has been profitable for more than two consecutive years. Customers have printed over 500 million parts on Formlabs' SLA and SLS platforms.
The Fuse X1 is available for order starting today, with shipments planned for the fourth quarter of 2026. Formlabs positions the device as a direct alternative to higher-cost industrial powder bed fusion systems, claiming it can reduce per-part costs by 50% and achieve three times the throughput of comparable systems. The system's build volume is 330 × 330 × 565 mm, with a packing density exceeding 30%, more than double the typical 10–15% upper limit of Multi Jet Fusion printers. The equipment can be installed in about an hour, fits through standard doorways, operates on single-phase power, and requires no dedicated HVAC (Heating, Ventilation, and Air Conditioning) requirements.
Formlabs has introduced two proprietary technologies for the Fuse X1. Adaptive Thermal Control manages 13 independent thermal zones within the build chamber, processing 700 times more thermal data per second than the Fuse 1+ 30W model, ensuring stable printing conditions from the first layer to the last. Print Intelligence is an AI-based computer vision system that uses real-time thermal imaging to monitor each layer, detect anomalies, and selectively remove affected parts from subsequent layers, thereby reducing material waste.
The complete ecosystem includes the Fuse X1 printer and modular build unit, the Fuse Sift X1 for powder recovery, a vacuum conveyor for automatic powder delivery, and the Fuse Blast post-processing unit in a high-capacity configuration.
In terms of customer applications, Tesla is using the Fuse X1 at its Gigafactory (Giga Nevada) to produce end-use parts and tooling. Cody Jepson, Additive Manufacturing Engineering Technician at Tesla Gigafactory, stated that with higher throughput and lower costs, the Fuse X1 has transformed how the lab supports projects. Radio Flyer reduced the prototype lead time for its Flyer Loop cargo e-bike frame from two months to just days. Product Development Engineer Agostino LoBello mentioned that now the entire frame can be printed overnight and assembled with bonding the next day.
Service provider Autotiv Manufacturing operates over 200 printers and ships 10,000 parts per week, expecting a return on investment five times faster than comparable SLS systems. During the four months prior to launch, Formlabs customers printed over 30,000 parts on early trial versions of the Fuse X1. The Fuse X1 will make its public debut on June 16 at the Reindustrialize Summit in Detroit, Michigan. Customers can also order parts printed on the Fuse X1 through Formlabs' new online 3D printing service, Form Now.
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