Formlabs, a global leader in professional 3D printing solutions, has introduced the Fuse X1, a next-generation large-format selective laser sintering (SLS) 3D printing ecosystem designed to make industrial additive manufacturing more accessible, efficient, and cost-effective for manufacturers, engineering teams, product developers, and service providers.
The newly launched system combines high-throughput production capabilities with a compact footprint, enabling businesses to manufacture production-grade parts at significantly lower costs than traditional industrial SLS systems. Starting at $84,999, the Fuse X1 delivers same-day production-quality components while offering up to three times higher throughput and as much as 50 percent lower cost per part compared to conventional powder-bed fusion technologies.
Designed to simplify industrial-scale manufacturing, the system features a build volume of 330 × 330 × 565 mm and supports packing densities exceeding 30 percent. The printer operates on standard single-phase power, requires minimal installation time, and eliminates the need for specialized facility modifications, making advanced manufacturing accessible to a broader range of organizations.
A key innovation within the Fuse X1 ecosystem is Adaptive Thermal Control technology, which continuously monitors thermal conditions throughout the build chamber. The system processes substantially higher levels of thermal data and manages multiple independent thermal zones to maintain optimal temperatures during production. This capability improves print consistency, maximizes build efficiency, and enables users to fully utilize available build space.
The platform also introduces AI-powered Print Intelligence, an advanced monitoring system that employs computer vision and thermal imaging to detect anomalies during the printing process. By identifying defects in real time and isolating affected parts, the technology minimizes material waste, improves reliability, and increases production success rates. The complete ecosystem includes the Fuse X1 printer, modular Build Unit, automated powder recovery and transportation solutions, and high-capacity finishing equipment designed to streamline post-processing operations.
Several leading organizations have already incorporated the technology into their manufacturing workflows. Automotive, consumer products, and industrial manufacturing companies have leveraged the system to accelerate product development cycles, expand production capacity, and improve return on investment through faster part production and reduced operational costs.
Formlabs also highlighted its growing momentum within the additive manufacturing industry. The company reported annual revenue exceeding $250 million in 2025, with customers collectively producing more than 500 million parts using Formlabs hardware and materials.
Formlabs is a global leader in professional 3D printing technology, dedicated to empowering innovators, engineers, manufacturers, and creators with accessible and advanced additive manufacturing solutions. Headquartered in Somerville, Massachusetts, with operations spanning multiple international markets, the company has grown into the largest professional 3D printing enterprise established since the 1980s.
With annual revenues exceeding $250 million, Formlabs has built a strong reputation for delivering industry-leading technologies that support product development, manufacturing, healthcare, education, and consumer applications. Customers worldwide have produced more than 500 million parts using Formlabs’ comprehensive portfolio of hardware, software, and materials. The company offers an extensive range of stereolithography (SLA) and selective laser sintering (SLS) 3D printers, complemented by advanced post-processing systems, intuitive software platforms, and a portfolio of over 45 specialized materials designed to meet diverse industrial and commercial requirements.
Driven by continuous innovation and a commitment to expanding access to digital manufacturing, Formlabs continues to help organizations accelerate product development, improve operational efficiency, and bring new ideas to market faster. In recognition of its contributions to the manufacturing sector, the company was named among the World’s Most Innovative Companies in Manufacturing by Fast Company in 2024.
