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Formlabs Fuse 1 - User Manual

Formlabs Fuse 1
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Manual Fuse 1
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Summary

Preface

1.1 Read and Retain Instructions

Importance of understanding and following safety instructions for safe operation.

1.2 Obtaining Documentation and Information

Resources for accessing manuals, support, and service providers.

1.2.1 Support and Service

How to obtain technical support and warranty services.

1.2.2 Warranty

Information regarding the product warranty and its terms.

Introduction

2.1 Intended Use

Defines the purpose and limitations of the Fuse 1 printer.

2.2 Technical Specifications

Lists key technical data and performance metrics of the Fuse 1.

2.3 Product Components

Identifies and describes the main external parts of the Fuse 1.

2.4 Fuse 1 User Interface

Explains the touchscreen interface and its operational functions.

Safety

3.1 Component and Subsystem Safety

Safety precautions for electrical and mechanical components.

3.1.2 Laser Safety

Warnings and guidelines related to laser radiation hazards.

3.1.3 Powder Safety

Essential safety practices for handling SLS powder.

3.1.4 Radio Interference

Information on FCC compliance and radio frequency emissions.

3.1.5 Ethanol Safety

Precautions and safe handling procedures for ethanol.

3.2 Personal Protective Equipment (PPE)

Details the required protective gear for safe operation.

3.3 Tool Specifications

Lists recommended tools and supplies for maintenance.

3.4 Sensitive Components

Highlights components vulnerable to damage and requiring care.

3.5 Emergency and Exceptional Situations

Procedures for handling emergencies like fire and substance spills.

Preparation and Setup

4.1 Location and Environs

Guidance on selecting an appropriate workspace for the printer.

4.2 Power and Networking

Specifies power requirements and network connection options.

4.3 Unboxing the Machine

Step-by-step instructions for safely unpacking the printer.

4.4 Accessing the Serial Name

Method for locating the printer's unique serial name.

4.5 Installing the Machine

Connecting cables, installing antenna, powering on, and leveling.

4.6 Setting Up a Network Connection

Details on connecting via Wi-Fi or Ethernet for network access.

4.7 Updating Firmware

Process for downloading and installing firmware updates.

4.8 Registering Powder Credit

How to load and manage powder credits for printing.

4.9 Preparing the Optical Cleaning Kit

Instructions for assembling and preparing cleaning supplies.

4.10 Transporting the Machine

Procedures for safely preparing the printer for shipping or relocation.

Printing

5.1 Operational Environment

Recommended conditions for optimal printing performance.

5.2 Designing for SLS

Guidelines for creating models optimized for SLS technology.

5.2.1 Printing Specifications

Key print parameters like build volume and layer thickness.

5.2.2 Feature Design Guidelines

Design recommendations for features like wall thickness and pin diameter.

5.3 Setting Up a Print

Process for preparing, orienting, and uploading print jobs.

5.3.1 Downloading or Updating PreForm

How to obtain the latest PreForm software version.

5.3.2 Preparing the File for Printing

Steps for importing, orienting, and saving models in PreForm.

5.3.2.1 Adding a Model

Importing multiple part files into PreForm for batch printing.

5.3.2.2 Orienting a Model

Adjusting model orientation for print quality and density.

5.3.2.3 Uploading a Print

Transferring the prepared print job to the printer.

5.4 Preparing for a Print

Essential maintenance steps required before starting a print.

5.4.1 Inserting the Build Chamber

Correct procedure for installing the build chamber.

5.4.2 Loading the Optical Cassette

Steps for inserting a clean optical cassette into the printer.

5.4.3 Filling the Hopper

Instructions for adding powder to the printer's hopper.

5.4.4 Checking the IR Sensor

How to inspect and clean the IR sensor for accurate readings.

5.4.5 Starting a Print

Initiating the print job from the printer's touchscreen.

5.5 Retrieving and Cleaning Prints with the Fuse Sift

Procedures for post-print handling and part recovery.

5.5.1 Cooling the Build Chamber in the Fuse 1

Allowing the build chamber to cool within the printer.

5.5.2 Cooling the Build Chamber in the Fuse Sift

Further cooling steps after moving to the Fuse Sift.

5.6 Managing the Machine

Tracking usage, managing jobs, and preparing for future prints.

5.6.1 Registering on Dashboard

Connecting the printer to the Formlabs Dashboard for monitoring.

5.6.2 Starting an Uploaded Print

Initiating a print job that has already been transferred to the printer.

5.6.3 Deleting an Uploaded Print Job

Removing unwanted print jobs from the queue.

5.6.4 Turning Off

Proper procedure for powering down the Fuse 1.

Maintenance

6.1 Tools and Supplies

List of tools and consumables required for maintenance.

6.2 Inspection and Maintenance

Overview of inspection tasks and maintenance schedules.

6.2.1 Before Each Use

Essential checks and cleaning before starting a print.

6.2.2 Periodic Maintenance

Schedule and tasks for routine maintenance.

6.3 Tasks Between Uses

Cleaning and checks to perform between printing sessions.

6.3.1 Cleaning the Optical Cassette

Detailed steps for cleaning the optical cassette.

6.4 Periodic Maintenance

Procedures for recurring maintenance tasks.

6.4.1 Cleaning the Camera Lens

How to clean the printer's camera lens for clear visibility.

6.4.2 Cleaning the IR Sensor Housing

Procedure for cleaning the IR sensor housing.

6.4.3 Cleaning the Exhaust Filter

Steps for cleaning the exhaust filter to maintain airflow.

6.4.4 Cleaning the Intake Filter

Steps for cleaning the intake filter.

6.4.5 Cleaning the Print Enclosure

How to clean the interior of the print enclosure.

6.4.6 Purging the Exhaust Lines

Procedure for clearing powder from exhaust lines.

6.5 Intermittent Maintenance

Maintenance tasks performed less frequently or as needed.

6.5.1 Updating the Firmware

Process for updating the printer's firmware.

6.5.2 Replacing the Optical Cassette

Procedure for replacing a damaged optical cassette.

6.5.3 Replacing the Intake Filter

Procedure for replacing a clogged intake filter.

6.5.4 Replacing the Exhaust Filter

Procedure for replacing a clogged exhaust filter.

6.5.5 Cleaning the Upper Laser Window

Method for cleaning the upper laser window.

Troubleshooting

7.1 Collecting Diagnostic Logs

How to gather diagnostic logs for issue investigation.

7.2 Performing a Factory Reset

Steps for resetting the printer to factory default settings.

7.3 Cleaning After a Failed Print

Procedures to clean powder troughs after a print failure.

7.4 Troubleshooting Errors or Abnormal Activity

Common errors, their causes, and proposed solutions.

7.4.1 Resolving Abnormal Functions

Troubleshooting steps for unresponsive machine or touchscreen.

7.4.2 Resolving Print Failures and Errors

Diagnosing and fixing common print failures.

Disassembly and Repair

8.1 Tasks

Guidance on contacting support for repair instructions and authorization.

Recycling and Disposal

9.1 Disposal of Powder

Guidelines for properly disposing of unsintered and sintered powder.

9.2 Recycling of Powder

Information on recapturing and reusing unsintered powder.

9.3 Disposal of Cleaning Agents

Safe disposal methods for used solvents and cleaning agents.

9.4 Recycling of Solvent

Options for solvent recycling to reduce costs and environmental impact.

9.5 Disposal of Electronic Components

Proper disposal of electronic parts and packaging according to guidelines.

9.6 Disposal of Packaging Waste

Guidelines for disposing of packaging materials responsibly.

Formlabs Fuse 1 Specifications

General IconGeneral
TechnologySelective Laser Sintering (SLS)
Layer Thickness110 microns
Laser TypeFiber laser
Laser Power10 W
SoftwarePreForm
Operating Temperature15-30 °C
Material CompatibilityNylon 12, Nylon 11
Weight114 kg
Laser Spot Size200 μm
Operating Humidity30-70% RH
Build Volume165 x 165 x 300 mm

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