Fuse 1


HP Jet Fusion 3D Series vs. Formlabs Fuse 1

High Performance Selective Laser Sintering, Finally Within Reach

Bring production-ready nylon 3D printing onto your benchtop with the Fuse 1, an affordable, compact selective laser sintering (SLS) platform.

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Compare the Formlabs Fuse 1 vs. HP Jet Fusion 3D Series



Fuse 1


Jet Fusion 3D Series


Starting at $21,249 USD. Complete setup starting from $38,925 USD.
Purchase from one of our certified APAC resellers with local on-site support capabilities. Prices exclude local VAT and shipping.  

Starting at $57,000-$110,000 for the 500/300 Series, $190,000 for the 4200 Series, $350,000 for the 5200 Series. Complete setups starting around $150,000-$500,000+.
Complicated and opaque pricing, requires multiple quote requests and negotiation.


Selective Laser Sintering (SLS)
The Fuse 1 is the first benchtop industrial SLS 3D printer that offers high quality, compact footprint, and a complete, simplified workflow at a fraction of the cost of traditional industrial SLS systems.

Multi Jet Fusion (MJF)
HP MJF 3D printers use an inkjet array that first deposits fusing, detailing, and coloring agents, and during another pass, exposes the powder bed to infrared energy which fuses the part’s layers together. While the process is different, the end result is similar to SLS.

Build Volume (W × D × H)

Fuse 1: 
16.5 x 16.5 x 30 cm
6.5 x 6.5 x 11.8 in

Jet Fusion 380/340:
Up to 25.4 x 19 x 24.8 cm 
Up to 10 x 7.5 x 9.8 in

Jet Fusion 580/540:
Up to 33.2 x 19 x 24.8 cm
Up to 13.1 x 7.5 x 9.8 in

Jet Fusion 5210/5200/4200:
38 x 28.4 x 38 cm
15 x 11.2 x 15 in


One popular material, more coming soon
The Fuse 1 currently prints with Nylon 12, the most popular SLS material that accounts for 90%+ of the market. Balancing strength and detail, Nylon 12 Powder is a highly capable material for both functional prototyping and end-use production of complex assemblies and durable parts with high environmental stability.
More materials are coming soon.

One to four materials, depending on the system
HP’s 500/300 Series 3D printers can produce parts only with Nylon 12, with no new materials added since their announcement. The 5210/5200/4200 models can print with Nylon 12, Nylon 11, TPE, and TPU.


Compact format and no special requirements
The Fuse 1 has a compact form and a low footprint. There is no need for inert gases and specialized air handling equipment. The lower energy consumption means that it can run on standard AC power without requiring specialized infrastructure.

Large space and specialized infrastructure
HP MJF 3D printers are substantially larger and their ecosystem comes with a larger operating footprint. They require specialized power infrastructure and a dedicated computer for print setup. These represent additional costs and time to the customer that are not captured in the quote.

Ease of Use

Plug and print
From print setup to powder recovery, our easy-to-use hardware and software are designed to maximize your efficiency at every step of the process. Easy workflow empowers anyone at your company to use the system independently after a quick online or in-person training.

Highly complex
Multi-day setup and training with on-site installation required. The complex workflow and the steep learning curve means that the system requires a skilled technician in-house to operate and maintain. 


Minimal waste
Parts in the Fuse 1’s build chamber can be packed tightly together to maximize density. Thanks to the 30% powder refresh rate for Nylon 12, you can print with up to 70% recycled powder for unlimited cycles. This means that you can print with minimal waste for tightly packed production builds.

The MJF process requires you to space parts widely apart to reduce the potential for thermal buildup. Recommended pack density is limited to roughly 8-10%, which means that you’ll need to throw away as much material as the amount that goes into the printed parts.


The Fuse 1 is designed for nonstop throughput. It comes with a removable build chamber, allowing you to start new prints within 1-2 hours after the previous print has finished to minimize downtime. Cooldown time takes only about half the print time for large builds, an industry-leading value that allows you to get to finished parts quickly.

The build chamber on HP’s 500/300 Series 3D printers is not removable, which means that you have to wait until the build fully cools down before starting the next print. Recommended cooldown time for MJF is 2x the print time, which means that the total time until parts are ready for post-processing is comparable to the Fuse 1. The 5210/5200/4200 models are optimized for higher throughput, but come at a much steeper price.


All in one
The Fuse Sift is a safe, efficient powder recovery system for the Fuse 1. This all-in-one station combines part extraction, powder recovery, storage, and mixing in a single free-standing device. Highly convenient and compact, this is the most functionality you'll get in a single device on the SLS market.

HP’s post-processing station offers similar functionality, but at an 8x higher price. 


The Fuse 1 is designed for minimal upkeep. The system offers proactive maintenance alerts and a full-color touchscreen interface guides you through every step of printing and maintenance.

A less user-friendly workflow means that the operator has to carry out a long list of manual maintenance steps between each print.


Free and easy to use
Formlabs' free print preparation software, PreForm, makes it easy to set up a print in minutes and offers advanced tools to manually refine as needed. Try it now. You can also use the online Dashboard to manage printers, materials, and teams. Available for Windows and Mac.

Paid and complicated
HP software solutions offer similar features, but using 3rd party software is also recommended, for an additional $12,000. Print setup requires intensive fine tuning, which results in a steep learning curve and the need for a skilled operator to prepare prints.


Standard and Premium Service
Up to three years of standard or premier support service with direct phone and email support, customized on-site training, on-site visits and repairs from local certified SLS experts, annual preventative checkups, and worry-free warranty—all for an affordable price.

HP offers multiple service tiers that offer similar benefits, but can easily cost around 10-20% of the price of the printer annually - enough to buy a complete Fuse 1 setup each year. 

Do you have more questions about the differences between these solutions?

Request a Free Sample 3D Print

See and feel Formlabs quality firsthand. We’ll ship a free sample part to your office.

Fuse 1 Sample Part

Build an Entire Factory for the Price of a Single HP 3D Printer

Buy a fleet of 4-6 Fuse 1s for the price of a single Jet Fusion 500/300 Series printer or build a factory with 20+ Fuse 1 units for the price of a single HP 5210/5200/4200 printer to scale your throughput, be able to print different materials simultaneously, and have peace of mind to avoid downtime.

Fuse 1 farm

High Quality Parts, Quickly and Affordably

Reduce costs, iterate faster, and bring better experiences to market with our advanced 3D printing materials designed to deliver beautiful final parts for a wide range of applications.

Print Cost


Print Time

28 hours


2 bindings

Weekly Throughput

10 bindings


70,000,000 Parts Printed With Formlabs Technology

Harvard University
From Fuse 1 to Fuse Sift:

A Convenient, Intuitive Workflow

Fuse 1 and Fuse Sift

Fast, Simple



print setup.

Use Formlabs PreForm print preparation software (free to download and try) to import STL or OBJ part files, orient and arrange models, estimate print times, monitor your printers, and upload job files.

PreForm’s part packing algorithms can automatically arrange many models in a build.

Try PreForm


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During setup and printing, an intuitive Touch UI walks you through every step.

The touchscreen displays a live stream of the print bed so you can watch each new layer take shape. This camera view is also available from your computer in PreForm so you can monitor your print without leaving your desk.

Track printers, teams, and supplies via the cloud-based Dashboard.


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SLS 3D printing fuses nylon powder layer by layer. The unused powder supports the parts during printing so you can create complex, interconnecting designs with no need for support structures.

With patent pending Surface Armor technology, a semi-sintered shell that prints around the surface of the part, the Fuse 1 provides competitive mechanical properties and surface finish without the prohibitive cost or hassle of competitor systems.

Powder Recovery

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powder recovery.

Our all-in-one powder recovery station, Fuse Sift, combines part extraction, powder recovery, storage, and mixing in a single device.

Produce fully-functional parts at a 30% powder refresh rate—with unlimited cycles. This means you can print with up to 70% recycled powder.

Fuse Sift will dispense and mix used and new powder automatically so you can reduce waste and control your powder supply.

Learn More: Fuse Sift

Nonstop Throughput

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nonstop throughput.

Add a second removable build chamber, compatible with the Fuse 1 and Fuse Sift, to enable continuous printing and reduce downtime.

Industry leading cooldown times allow you to start a print 1–2 hours after your previous print has finished.

A New Wave of Independent Manufacturing Starts Now

Rethink product development and take control of your own manufacturing. Configure your Fuse 1 setup today.