2025
We turned a single Fuse 1+ 30W into a lights-out SLS printing cell. Automated chamber swaps and powder cleanup deliver continuous, next-print-ready uptime.
SLS 3D Printing
Automation
Introduction
From overnight prints to next-print-ready uptime
At DHR we love selective laser sintering (SLS) because it delivers tough, accurate parts, straight from the powder. Unlike other additive manufacturing methods (like SLA or FDM), the surrounding powder itself acts as a natural support, which makes it possible to print complex geometries and fully functional assemblies in a single build. The parts come out consistently strong and are ideal for demanding industrial 3D printing applications, often lasting millions of cycles, which is something that we like to test a lot for other projects.
With this project we wanted to get more production capacity out of the Formlabs Fuse 1+ 30W platform. While the Fuse ecosystem is designed for high throughput, the manual post-processing steps between jobs still leave machines idle. We built a compact automation solution - a robotic cell that takes care of build chamber loading, unloading, and powder cleaning. The result is a continuous workflow that keeps the printer running long after the lights go out.
Problem
The Throughput Challenge: Why SLS Automation is Essential
SLS printing shines for functional parts, but manual steps slow it down. Typical Fuse 1+ jobs complete the same day, and 95% of fully packed jobs finish within 14 hours. That often lands completion in the middle of the night, when no one is there to unload, swap chambers, clean powder, and start the next run. Cooldown windows matter too. Formlabs designed the platform for 24/7 uptime with rapid cooldown so a new print can begin about 75 minutes after the previous job, if a second removable chamber is ready. Without automation, that window is easy to miss and capacity is left on the table.
Powder management is another friction point. The standard workflow uses the enclosed Fuse Sift station to de-cake parts and recycle powder under HEPA-filtered airflow. It keeps the process clean and safe, but the printer itself still needs a quick, consistent cleanup so seals, optics access points, and latches stay debris-free for the next cycle. Automating that cleaning step improves consistency, protects the machine, and preserves material handling discipline shift after shift.
Solution
One Robot Arm, Many Jobs: Tool-Changing Service for the Fuse 1+
We built a small-footprint service cell around a CPS tool changer so a single robot arm can handle the entire turn-over sequence without human intervention.
The same arm executes distinct tasks in one cycle with the following custom tools:
Servo gripper: plugs / unplugs the removable build chamber with precise force control; locks / unlocks the chamber in place.
Mechanical fork: lifts, transports, and loads / unloads chambers; closes the printer door.
Vacuum attachment: performs targeted powder cleanup inside the print bay.
The cycle is straightforward. When the print completes and cooldown permits, the robot opens the door, extracts the hot chamber, and stages it for post-processing. It then loads the next prepped chamber, confirms seating and interlocks, and executes a brief vacuum pass. With the bay clean and closed, the printer is clear to start the next job immediately. The tool-changer approach compounds advantages: flexibility across tasks, a single compact footprint, and easy scalability as new tools or steps are added.
We sized the system for three build chambers to keep a rolling buffer: one printing, one cooling or in post-processing, one staged and ready. That buffer pairs well with the platform’s rapid cooldown and same-day print profile, which is how we reach a practical 2× productivity increase on the same printer.
Conclusion
Scaling Up: From Printer Automation to Full Part Flow
This project marked our first deep dive into SLS automation, where we aimed to get more production capacity out of the Formlabs Fuse 1+ 30W platform. Soon after, we expanded the setup to include critical maintenance tasks like optical cassette cleaning and IR sensor cleaning. The automated service loop eliminates the dead time between jobs and makes overnight production routine. The Fuse 1+ runs at the pace its hardware allows, the chamber buffer keeps the queue moving, and consistent cleanup preserves print quality and machine health.
Next we are extending automation to part handling and depowdering. Formlabs’ enclosed powder workflow and materials portfolio already support this expansion path, which is why SLS is such a strong candidate for factory-grade automation in compact cells.
Ready to turn SLS into a continuous process in your facility? Tell us about your parts and throughput targets, and we will design the right automation cell for your Fuse series printers. Contact our team today.
If you're facing throughput challenges or planning your next production ramp — let’s talk. We work with hardware teams who build things that matter, and need their automation to move fast and perform flawlessly.