SLS Printing – Formlabs Fuse 1+ Fleet
Industrial nylon powder bed fusion for functional prototypes, end-use production parts, and complex geometries — without support structures.
Machine Specifications
Build Volume (per unit)
Powder bed — no supports needed
Dimensional Accuracy
Typical; tighter with calibration
Layer Thickness
Standard SLS layer height
Standard Lead Time
Express 24 h on request
Our Formlabs Fuse 1+ fleet operates as a continuous production system, delivering high-throughput SLS nylon parts at consistent quality. The powder bed process eliminates support material entirely, making it ideal for complex internal channels, living hinges, snap-fit assemblies, and interlocking components that other additive processes cannot produce in a single build. Fleet operation enables short lead times even for larger batches, with parts ready for dimensional inspection and surface finishing directly from the machine.
Best For
- Functional nylon parts with complex geometry
- Snap-fits and living hinges requiring ductility
- Assemblies with interlocking or nested components
- End-use production parts in small-to-medium batches
- Jigs, fixtures, and tooling aids
- Parts where support removal would damage geometry
Not Ideal For
- Optical clarity or transparency requirements
- Continuous service above 160 °C
- Parts requiring a smooth Class-A cosmetic surface (as-built is slightly textured)
- Very large single pieces exceeding 300 mm in any axis
- Applications requiring natural white — as-built SLS is grey/beige
Typical Parts We Produce
Functional Brackets & Housings
PA12 or PA11; typically ordered in batches of 5–200 units
Snap-Fit & Living Hinge Assemblies
Single-build interlocking parts; PA11 for maximum flex cycles
Ductwork & Manifolds
Complex internal channels; support-free geometry advantage
Jigs, Fixtures & Tooling Inserts
Production aids; PA12-GF for stiff, wear-resistant tooling
End-Use Production Parts
5–500+ unit batches; fleet capacity supports parallel builds
Flexible Seals & Grippers
TPU 88A; support-free complex elastomeric geometry
Quality & Repeatability
All Fuse 1+ builds are produced with calibrated, validated powder refresh ratios to ensure consistent mechanical properties batch-to-batch. Each order includes a dimensional spot-check at critical features, and full GD&T inspection reports are available on request. Parts are visually inspected for sintering defects before dispatch. Certificate of conformance available for production orders.
Supported Material Categories
PA12 — Nylon 12
Industry-standard engineering nylon. Excellent chemical resistance and dimensional stability.
PA11 — Bio-Based Nylon 11
Higher impact resistance and elongation at break vs PA12. Preferred for dynamic loading.
PA12-GF — Glass-Filled Nylon
30% glass fiber reinforcement. High stiffness, low creep, HDT up to 175 °C.
TPU 88A — Flexible Elastomer
Rubber-like SLS material for seals, grippers, and shock-absorbing components.
Ready to produce with the Formlabs Fuse 1+?
Upload your CAD file for an instant price, or speak to our engineering team to discuss your specific requirements and tolerances.