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formlabs Fuse 1, Manual

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54

8 

Disassembly and repair

All steps that involve opening the machine and/or investigating internal components should be 
done by skilled persons under the guidance of Formlabs Support or a certified service provider. 
Any damage resulting from attempting disassembly and/or repair without prior authorization 
from Formlabs Support or a certified service provider is not covered by warranty.

8.1 

Tasks

Contact 

Formlabs Support

 or a 

certified service provider

 to receive repair instructions and 

authorization, including how to disassemble or remove the exterior paneling.

Task

Frequency

Replacing the build chamber piston seal

When advised by Formlabs Support or a certified 

service provider

Replacing the print enclosure door seal

When advised by Formlabs Support or a certified 

service provider

Replacing the laser fan mesh

When advised by Formlabs Support or a certified 

service provider

Replacing the quartz heaters

When advised by Formlabs Support or a certified 

service provider

Replacing the IR sensor

When advised by Formlabs Support or a certified 

service provider

Any other maintenance or repair tasks not listed in section 

6 Maintenance

 requires servicing 

the machine. Contact 

Formlabs Support

 or a 

certified service provider

 to request in-field 

service or an RMA (short for “return to manufacturer authorization”).

Summary of Contents for Fuse 1

Page 1: ...Manual Fuse 1 ...

Page 2: ......

Page 3: ...llation and Usage Instructions Fuse 1 Benchtop Selective Laser Sintering SLS 3D printer Original English instructions Read this manual carefully and keep it for future reference January 2021 REV 01 Formlabs ...

Page 4: ...5 Emergency and exceptional situations 19 4 Preparation and setup 21 4 1 Location and environs 21 4 2 Power and networking 22 4 3 Unboxing the machine 22 4 4 Accessing the serial name 23 4 5 Installing the machine 24 4 6 Setting up a network connection 25 4 7 Updating firmware 26 4 8 Registering powder credit 26 4 9 Preparing the optical cleaning kit 28 4 10 Transporting the machine 29 5 Printing ...

Page 5: ...forming a factory reset 51 7 3 Cleaning after a failed print 51 7 4 Troubleshooting errors or abnormal activity 52 8 Disassembly and repair 54 8 1 Tasks 54 9 Recycling and disposal 55 9 1 Disposal of powder 55 9 2 Recycling of powder 55 9 3 Disposal of cleaning agents 55 9 4 Recycling of solvent 55 9 5 Disposal of electronic components 56 9 6 Disposal of packaging waste 56 10 Index 57 11 Glossary ...

Page 6: ......

Page 7: ...r integrator to perform the appropriate and complete risk analysis evaluation and testing of the products with respect to the relevant specific application or use thereof Neither Formlabs nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information that is contained herein Notify us if you have any suggestions for improvements or amendments or have found e...

Page 8: ...d the contents of this manual Ensure that each person who uses the Fuse 1 has read these warnings and instructions and follows them Formlabs is not liable for cases of material damage or personal injury caused by incorrect handling or non compliance with the safety instructions In such cases the warranty will be voided 1 2 Obtaining documentation and information Visit formlabs com to Access your F...

Page 9: ...2143 Germany Formlabs GmbH Nalepastrasse 18 12459 Berlin Germany 1 2 2 Warranty This product is protected under warranty Formlabs offers a warranty for all Formlabs branded hardware Unless otherwise expressly stated the Terms of Service including the Warranty constitute the entire agreement between you and Formlabs with respect to the Service and any product you purchase from Formlabs and supersed...

Page 10: ...SLY DISCLAIMS ANY IMPLIED OR EXPLICIT WARRANTY OF FITNESS for a particular usage the particular nature and circumstances of said usage being unforeseen and unforeseeable to Formlabs Formlabs is not a manufacturer of medical devices Formlabs provides tools and materials that may be used in many applications but makes no claims as to the safety or effectiveness of any specific devices made using For...

Page 11: ...lements Positive temperature coefficient PTC cartridges Air handling Pressure controlled two stage filtration Replaceable HEPA and carbon mediums Power requirements EU 230 VAC 7 5 A dedicated circuit US 120 VAC 15 A dedicated circuit Laser specifications EN 60825 1 2014 Class 1 laser product 1065 nm Maximum 10 W 4 01 mrad beam divergence nominal full angle Laser spot size FWHM 200 μm 0 0079 in Rad...

Page 12: ...om entering and powder from leaving the hopper Hopper Stores up to 9 kg 19 8 lb of powder for printing Hopper window Allows for visual check of powder level in the hopper Door handle A grab slot to help close the door Cassette tray Holds the optical cassette in place Build chamber latch Secures a build chamber Print enclosure Houses the build chamber and optics system for printing Build chamber so...

Page 13: ...loseandopenthecartridgevalve Handles For holding and lifting the cartridge 2 3 4 IR sensor Sensor window The exposed surface that allows infrared radiation to enter the sensor Ethernet socket Used to connect the sensor to the printer and disconnect for cleaning Status light Indicates if the sensor is seated correctly green or incorrectly yellow 2 3 5 Optical cassette Laser window gasket Seals the ...

Page 14: ... is deposited and sintered into parts Thermal insulated silicone gloves For removing the build chamber while it s still hot Push top dispensers For dispensing Alconox deionized water and ethanol to clean the optical cassette Polyester swabs For cleaning the upper laser window the IR sensor and the IR sensor housing PEC PADs For cleaning the cassette s optical windows Telescoping mirror For inspect...

Page 15: ...atus card is the Next Job card which presents the next print job in the queue The slider to unlock the print enclosure is located in the bottom right corner of the touchscreen Tap the printer icon in the left sidebar to access the printer status screen Readouts of the bed temperature hopper level powder type and available credits can be found here The Fuse 1 requires periodic maintenance and notif...

Page 16: ...ndicates information considered important but not hazard related DANGER Ethanol is a flammable chemical DANGER CLASS 4 INVISIBLE LASER RADIATION WHEN OPEN AND INTERLOCKS DEFEATED AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION WARNING Class 1 laser product Only remove the exterior paneling of the printer with authorization from Formlabs Support or a certified service provider ENVIRONME...

Page 17: ...ow these procedures will result in serious injuries including burning and or scalding of skin Due to its size and weight do not move or reposition the Fuse 1 alone If the machine needs to be moved at least two or more individuals should use the lifting straps provided with the printer Do not lift or reposition the Fuse 1 By grabbing or pulling on the print enclosure door hopper hopper lid filter c...

Page 18: ...s Parameter Unit Diode 1065 nm Maximum output 10 W Beam divergence 4 01 mrad nominal full angle Certification ISO 11553 1 2020 ISO 11252 2013 ISO 11554 2017 3 1 3 Powder Dust deposits should not be allowed to accumulate on surfaces Clean dust residues at regular intervals Do not use brooms or compressed air hoses to clean surfaces Only use a compliant vacuum that is grounded and bonded such as a C...

Page 19: ...mlabs powder is not approved for use with food drink or medical applications on the human body Refer to the safety data sheet SDS for each specific powder as well as support formlabs com for more detail 3 1 4 Radio interference Note This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provi...

Page 20: ...ended when handling loose or unsintered powder as it may draw moisture and oils out of skin If powder is handled at room temperature it is not necessary to wear protective gloves Safety glasses Required when performing maintenance on the Fuse 1 as well as handling loose or unsintered powder at any time Polycarbonate based lenses including prescription glasses are acceptable so long as they provide...

Page 21: ...ure and as a secondary interlock measure for the laser Refer to section 5 4 4 Checking the IR sensor for more information Optical windows There are two individual optical windows contained within the cassette assembly both of which need to be inspected after each print and cleaned regularly They protect the camera and upper laser window Refer to section 6 3 1 Cleaning the optical cassette for more...

Page 22: ...tely leave the area and close the door of the room behind you 5 Evacuate the building according to your organization s emergency protocols 6 Call emergency services once you have reached a safe distance from the fire 3 5 2 Ethanol When handling ethanol always consult the safety data sheet SDS from the ethanol supplier as the primary source of information Handle ethanol with gloves in a well ventil...

Page 23: ...85 8 in The Fuse Sift footprint is 99 1 61 0 157 0 cm 39 0 24 0 61 8 in With the hood open the Fuse Sift is 188 8 cm 74 3 in in height Leave at least 61 cm 24 in to the left front and right of the unit free for access Place the Fuse Sift at least 20 0 cm 8 0 in from nearby walls Do not overlap with the Fuse 1 access footprint by more than 30 5 cm 12 0 in 3 Ensure proper ventilation is installed Si...

Page 24: ...wo person lift is required to prevent injury and avoid damage to the machine 4 3 1 Receiving The standard Fuse 1 package ships on a pallet and contains the Fuse 1 printer stand build chamber and powder cartridge Additional powder cartridges and accessory boxes ship separately from the printer s packaging Depending on the package you purchase the accessories may ship together on a pallet If you are...

Page 25: ...oop so they do not go past your elbows 7 With your back straight and knees slightly bent brace against the machine with your palms as you and a second person lift the unit up 8 Carefully move the printer onto the stand keeping the four feet aligned with the corresponding recesses on the stand If you need to readjust the machine use the lifting straps to pick it back up Do not pick up the machine w...

Page 26: ...on the machine 1 Plug the included power cable into the power port on the back of the unit and connect the power cable to a dedicated circuit 2 Flip the breaker switch on the back of Fuse 1 to the ON position to turn on the machine 3 AstheFuse1initiates theFormlabslogowithaprogressbarappearsonthetouchscreen followed by the onboarding process Follow the on screen prompts to finish setting up the ma...

Page 27: ...ap the wrench icon on the Home screen The Settings screen appears 2 Tap Connectivity Wi Fi The Wi Fi screen appears 3 Toggle Use Wi Fi to ON The toggle turns blue 4 Tap the desired wireless network 5 If prompted enter your network password and tap the checkmark to confirm 4 6 2 Connecting with Ethernet The rear of the unit is equipped with a RJ 45 Ethernet 10BASE T 100BASE TX 1000BASE T 1000 Mbit ...

Page 28: ...load the latest firmware and then upload the file to the machine To upload firmware the device must be connected to the computer via USB or the machine must be connected to an Ethernet network 9 The machine may automatically recognize that you have sent a firmware update Tap Continue on the touchscreen to finish the installation 10 If you are not prompted to Continue continue the firmware update m...

Page 29: ...ove the card from the card holder 5 Close the IR sensor door 4 8 2 Checking available powder credit When not loading or unloading powder credit onto the printer you can check how much credit is available This information can be found on the Printer Status screen To check available powder credit 1 Tap the printer icon in the left sidebar on the touchscreen The Printer Status screen appears 2 All av...

Page 30: ...tered to the printer Register additional powder credits or order additional powder 4 9 Preparing the optical cleaning kit The Fuse 1 comes with three push top dispensers for the Alconox distilled water and ethanol used to clean the optical cassette Each dispenser is dedicated to one cleaning agent The three cleaning agents must be purchased separately Below is a list of Formlabs approved distribut...

Page 31: ...ckage for product weight and dimensions Keep the packaging for transportation or shipping The complete packaging kit consists of one 1 pallet plywood and foam one 1 optics protector cardboard and foam one 1 inner C fold cardboard and foam one 1 protective bag plastic one 1 outer C fold cardboard and foam one 1 protective pad cardboard one 1 topper cardboard and foam two 2 lifting straps 4 10 1 Pre...

Page 32: ... 2 Packaging Thoroughly read and follow the instructions to properly package the machine Skipping any of the following steps may result in shipping damage and void the warranty To package the machine 1 Open the air filter door and pull the door release to open the print enclosure door Place the optics protector in the optical cassette tray with the foam side facing up Close and secure the optical ...

Page 33: ...the hopper lid 10 Loop two nylon binding straps commercially available through the pallet and vertically around the printer Loop the straps through the small holes in the pallet underneath the platform 11 Crimp the binding straps on the protective pad to protect the printer from scratches The printer should be rigidly attached to the pallet 12 Encase the machine with the inner C fold segment 2 lea...

Page 34: ...ng SLS enables the construction of parts without the use of support structures often required with SLA or FDM printing platforms This allows parts to be tightly packed into a single print job however there are some limitations that must be taken into account Sintered powder is sensitive to sudden and drastic temperature changes Allow the build chamber to steadily and fully cool down after a print ...

Page 35: ...1 print jobs can be set up using PreForm the dedicated print preparation software for Formlabs printers To start open OBJ or STL files in PreForm orient and layout multiple models into a complete build then send the print job to the machine 5 3 1 Downloading or updating PreForm Visit the PreForm product webpage to download the latest version formlabs com software Learn how to use PreForm from the ...

Page 36: ...nt job from PreForm to the machine 1 Click the orange printer icon on the Home screen The Print window opens 2 Click the Select Printer arrow to select a printer The Printer List window opens 3 Click the name of a printer you wish to select The Printer Details window opens If the printer does not automatically appear in the Printer List click Add to manually enter the printer s IP address Ensure t...

Page 37: ...every print Check that the optical cassette is clean before inserting it into the printer Wear clean nitrile gloves when handling the optical cassette Powder skin oils and other contaminants may smudge the windows To load the optical cassette 1 Loosen the thumb screw in the front center of the ceiling of the print enclosure The cassette tray swings down into the print enclosure 2 Remove the used o...

Page 38: ...ult to reach for some users If necessary keep a step stool nearby To check the IR sensor 1 Open the IR sensor access door on the top of the printer 2 Locate the IR sensor which has a grey cap with an LED in the center The LED turns green or orange depending on the status of the IR sensor 3 Grip the cap and pull the IR sensor off its mount The IR sensor is held in place with magnets and should come...

Page 39: ... not handle parts from a build chamber without allowing the entire print enclosure to cool for several hours or until the print bed temperature has reached 45 ºC 113 F Use the provided thermal insulating silicone gloves when removing a build chamber that has not been allowed to cool down Failure to follow these procedures will result in serious injuries including burning and or scalding of skin A ...

Page 40: ...dashboard allows individuals and teams to remotely monitor Formlabs devices track material usage and explore past and future Formlabs purchases Register the Fuse 1 to Dashboard through the touchscreen Once the printer is registered to Dashboard and Dashboard Logging is enabled on the printer the Fuse 1 sends data to Dashboard as long as the printer s Wi Fi or Ethernet connections are able to acces...

Page 41: ...nly as described When removing the exterior paneling disconnect the machine from its power source before maintenance Moving parts present crushing and tangling hazards Formlabs provides instructions to advise skilled and unskilled persons in installing operating and maintaining the Fuse 1 The Fuse 1 shall only be maintained by a qualified and trained person Do not open the Fuse 1 and or investigat...

Page 42: ...l cassette with the same cleaning agent Polyester cloth swabs Disposable lint free polyester cloth swabs with either orange or blue plastic handles for cleaning the IR sensor and camera lens Do not reuse a polyester swab dispose of after each use 6 2 Inspection and maintenance 6 2 1 Before each use Inspect Refer to Section Installation environment Operational environment 5 1 Optical cassette Clean...

Page 43: ...ully repeat the procedure Small blemishes or color differences do not affect print success or quality Before cleaning An optical cassette removed from the Fuse 1 after a print job The optical cassette shows defined streaking and clouding After cleaning An optical cassette after cleaning with Alconox distilled water and ethanol to remove the contamination To inspect the optical cassette 1 Remove th...

Page 44: ...w If there are visible streaks or deposits or sections look foggy repeat the procedure To fully clean the optical cassette if standard cleaning is insufficient 1 Put on a pair of new clean nitrile gloves Powder skin oils and other contaminants may smudge the windows on the optical cassette 2 Place the dirty optical cassette with the gaskets facing down on a flat clean surface 3 Wet a new PEC PAD w...

Page 45: ...he IR sensor housing 6 4 2 Cleaning the exhaust filter After 30 hours of printing Cleaning the exhaust filter 6 4 3 Cleaning the intake filter After 30 hours of printing Cleaning the intake filter 6 4 4 Cleaning the print enclosure After 100 hours of printing Cleaning the print enclosure 6 4 5 Purging the exhaust lines After 10 15 full build volume prints or 500 hours of printing whichever comes f...

Page 46: ...11 Return a clean optical cassette to the window tray 12 Return the cassette tray to its closed position Tighten the thumb screw until it fully engages 13 Close the print enclosure door Press firmly to ensure that the door is fully latched If necessary squeeze the door shut using the cutout on the right side of the printer for leverage 6 4 2 Cleaning the IR sensor housing The IR sensor housing sho...

Page 47: ...ate to the filter maintenance procedure by tapping the checklist icon on the Print Status screen or b Drag the Open Door slider on the touchscreen 2 Open the air filter door on the right side of the printer 3 Disconnect the vacuum hose from the side of the Fuse Sift 4 Turn on the vacuum by pushing the Vac button on the control panel or by tapping the vacuum hose icon on the touchscreen 5 Vacuum th...

Page 48: ...s screen or b Drag the Open Door slider on the touchscreen 2 Open the air filter door on the right side of the printer 3 Disconnect the vacuum hose from the side of the Fuse Sift 4 Locate the conical intake filter located on the left side of the filter cabinet 5 Grip the base of the conical filter and gently twist it counter clockwise to disengage the snap fit tabs Remove the filter from the filte...

Page 49: ...re door unlocks 2 Open the print enclosure door on the printer Ensure that the print enclosure door is open before continuing If the print enclosure door remains shut while you purge the exhaust lines powder may be drawn from the hopper into the print enclosure and cause the next print to fail 3 Open the air filter door on the right side of the printer 4 Turn off the printer using the rear breaker...

Page 50: ...r 1 000 hours of printing or if print quality indicates contaminated optics Inspect the upper laser window after every 100 hours of printing Cleaning the upper laser window 6 5 5 Cleaning the powder troughs If powder becomes contaminated with fiber or other debris or instructed to do so by Formlabs Support or a certified service provider Cleaning after a failed print 7 1 6 5 1 Updating the firmwar...

Page 51: ... a new clean pair of nitrile gloves Powder skin oils and other contaminants may smudge or damage the clean laser window 2 Drag the Open Door slider on the touchscreen The print enclosure door unlocks 3 Open the print enclosure door 4 Loosen the thumb screw in the front center of the ceiling of the print enclosure The cassette tray swings down 5 Slide the optical cassette out of the cassette tray 6...

Page 52: ...er window is clean and clear of obstruction If there are streaks or debris on the upper laser window repeat this cleaning procedure with a new polyester cloth swab 15 Loosen the thumb screw in the front center of the ceiling of the print enclosure The optical tray drops down 16 Return a clean optical cassette to the cassette tray 17 Return the cassette tray to its closed position and tighten the t...

Page 53: ...er Before starting a new print clean out the powder troughs to reduce the likelihood of another failed print Powder that comes into contact with fibers or other contaminants e g in a vacuum cleaner cannot be filtered and should be disposed of To clear debris or obstructions from the powder troughs 1 Slide the Unlock Door toggle on the touchscreen to open the print enclosure 2 Unplug and remove the...

Page 54: ...arting contact Formlabs Support or a certified service provider for additional guidance Unresponsive touchscreen Buttons or controls on the touchscreen do not respond to touch input One off firmware glitch Loose connection with the touchscreen 1 Power cycle the machine by flipping the breaker switch on the back of the unit to OFF and back to ON 2 Check whether the machine is running the latest fir...

Page 55: ...e is too high Check whether the IR sensor housing has any laurolactam built up in the sensor field of view Refer to section 6 4 2 Cleaning the IR sensor housing for more information Melting The powder on the surface of the print is blackened due to melting Heaters heated the powder to above its melting temperature The heaters or the IR sensor may be malfunctioning Contact Formlabs Support or a cer...

Page 56: ... paneling Task Frequency Replacing the build chamber piston seal When advised by Formlabs Support or a certified service provider Replacing the print enclosure door seal When advised by Formlabs Support or a certified service provider Replacing the laser fan mesh When advised by Formlabs Support or a certified service provider Replacing the quartz heaters When advised by Formlabs Support or a cert...

Page 57: ...ing the Fuse Sift for use in future prints The Fuse 1 can print with up to 70 recycled powder Formlabs does not operate a recycling program 9 2 2 Sintered powder or cleaned parts Discard cleaned parts and sintered powder with household items as trash Cleaned parts and sintered powder cannot be recycled 9 3 Disposal of cleaning agents Safe and appropriate disposal methods of used solvent vary by lo...

Page 58: ...cycling of waste of electrical and electronic equipment By disposing of the device in the proper manner you help avoid possible hazards for the environment and public health that could otherwise be caused by improper treatment of waste equipment The recycling of materials contributes to the conservation of natural resources Therefore do not dispose of your old electrical and electronic equipment w...

Page 59: ...12 40 43 44 45 53 57 L laser 6 9 11 12 14 16 19 48 49 50 53 54 57 59 60 61 laser window laser 6 9 11 12 14 16 19 48 49 50 53 54 57 59 60 61 level 10 13 14 23 24 25 31 57 leveling 24 57 M maintenance 5 13 14 15 18 19 34 39 40 43 45 46 48 54 57 N nylon 21 31 57 59 O operation 6 14 15 18 57 optical cassette 10 11 12 19 23 28 29 30 35 38 40 41 42 43 44 47 48 49 50 57 60 optical window 42 57 optical wi...

Page 60: ...8 temperature 9 11 13 15 18 32 36 37 53 58 59 heat 9 11 13 15 18 32 36 37 53 58 59 touchscreen 9 13 19 23 24 25 26 27 34 35 37 38 39 43 44 45 46 47 49 51 52 58 U USB 9 24 25 26 30 34 58 V vacuum 16 18 21 30 40 45 46 47 51 58 ...

Page 61: ... is the second agent used for wiping off residual alconox from the previous cleaning step Ethanol A simple alcohol that is the recommended denaturing agent for removing deposits of laurolactam and other off gassing stains from the printer s optics Flippers Two paddles one on the left and right side of the powder handling system that move powder into position for the recoater roller to pick up and ...

Page 62: ...r cartridge The container in which printing powder is mixed and transported from the Fuse Sift to the printer s hopper Holds 3 kg 6 6 lb of powder Polyester cloth swab A disposable lint free polyester cloth swab with a plastic handle that is used for cleaning the printer s IR sensor and camera lens Do not reuse a polyester cloth swab dispose of after each use PreForm Orient and lay out models in P...

Page 63: ...Directive 2006 42 EC A Type Standards EN ISO 12100 2010 B Type Standards EN 60204 1 2018 C Type Standards None Laser ISO 11553 1 2020 ISO 11252 2013 ISO 11554 2017 Electromagnetic Compatibility 2014 30 EU IEC 61000 6 2 IEC 61000 6 4 Chemicals and waste Restriction of Hazardous Substances Directive 2011 65 EU EC No 1907 2006 Chemical Substances REACH Regulation ...

Page 64: ...Original English instructions January 2021 Formlabs ...

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