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Replacing the Fuse 1 generation door latch and striker

On Fuse 1 generation printers, the print enclosure door is held closed with a latch. If either the latch in the printer body or the striker on the door is faulty or damaged, the door may not open or stay closed properly, preventing you from using the printer.

Use this guide to replace the print enclosure door latch and striker on a Fuse 1 generation printer.

Required supplies:

Formlabs:

Fuse 1 generation door accessories kit (RP-FS1-DA-01)

Third-party:

2.0 mm hex driver (flat-end)
2.5 mm hex driver (flat-end)
3 mm hex driver (ball-end) or hex key

Estimated time: 30–45 minutes

Danger:

Read and follow all safety instructions and warnings in the operator manual. Replacement with incorrect parts can lead to burns, shock, fire, or explosion. Dispose of all parts in accordance with local regulations.

Warning:

Do not perform this procedure if the printer was printing less than six hours prior. Failure to do so may result in serious burns. Allow the print enclosure to cool to room temperature before touching or inspecting any Fuse 1 components.

Preparing the workspace

Overview: Prepare the printer and a dust-free workspace for replacing the print enclosure door latch and striker.

Notice:

Fuse 1 generation printers contain sensitive electronic components. Ground yourself before touching any electronics in the printer by using a grounding strap or touching a grounded piece of metal.

Step 1: Prepare the workspace

Clear a workspace around your printer. Ensure that the workspace is well-ventilated and free of dust.

Step 2: Unplug the printer

Disconnect the power cable before continuing with maintenance. Do not perform maintenance on the printer while it is connected to power. Wait five minutes after disconnecting the printer from power before proceeding.

Danger:

Performing maintenance on the printer while it is plugged in increases the risk of electric shock. Never remove the back panel of the printer while the printer is plugged in. Never reconnect the printer to power while the back panel is uninstalled.

Removing the hopper-side panel

Overview: Remove paneling on the hopper side of the printer to access the door latch.

Step 1: Begin removing the hopper-side panel screws

Using a 2.5 mm hex driver, loosen and remove the two black (circled in red) and one chrome (circled in blue) 8.0 mm M4 button head screws from the back-left of the printer. Take note of the locations of these screws, as the placement of the chrome screws is critical to the printer's electrical grounding. Set the screws aside.

Step 2: Continue removing the hopper-side panel screws

Move to the hopper side of the printer. Using a 2.5 mm hex driver, loosen and remove the 10 M4 countersunk screws holding the hopper-side panel to the printer. Remove the top-most 6.0 mm countersunk screws last to make removing the panel easier. Set the screws aside.

Three 16.0 mm screws, circled in green
Three 12.0 mm screws, circled in blue
Four 6.0 mm screws, circled in red

Step 3: Tilt the hopper-side panel

Allow the panel to tilt away from the printer, allowing access to the interlock switch cables. Do not remove the panel at this time.

Step 4: Disconnect the interlock switch and remove the hopper-side panel

Locate the black and red cables leading to the interlock switch on the inner left-hand side of the panel. The cables are retained by a cable clamp. Unlock the cable clamp and disconnect the cable labeled C033.

Separate the hopper-side panel from the printer, taking care to ensure that none of the cables are caught or tangled. Set the panel down on a flat, clean surface.

Step 5: Open the print enclosure door

Open the print enclosure door by pulling the manual release handle in the filter cabinet.

Step 6: Remove the manual release handle

Remove the build chamber socket & cable harness

Pull the cable through the manual release handle to expose the ferrule, then slide the cable out of the handle. Set the manual release handle aside.

Removing the door latch

Overview: Disconnect and remove the original door latch mechanism.

Step 1: Locate the door latch assembly

Locate the door latch assembly, positioned behind the filter cabinet.

Step 2: Disconnect the door latch cable

The door latch cable terminates in two connectors, visible next to the latch assembly. For both, squeeze the locking tab, then separate the connectors. Do not pull on the wires themselves.

Step 3: Unscrew the door latch mounting screws

Using a 3 mm ball-end hex driver or key, loosen and remove the four 5 mm button head screws holding the door latch in place. Set the screws aside.

Step 4: Remove the door latch

Slide the latch assembly forward and remove it from the printer. Take care that the door latch cable and the manual release cable do not catch on any of the nearby printer components. Set the latch assembly aside for disposal with electronic waste.

Installing the replacement door latch

Overview: Mount and secure the replacement door latch assembly.

Step 1: Mount the replacement door latch

Slide the new door latch assembly into place. Feed the black cable through to the back of the mounting plate. Feed the manual release cable through the slot at the top of the mounting plate.

Step 2: Align and secure the latch assembly

Align the front of the latch assembly with the front of the mounting plate. Thread one 5 mm M4 screw into each of the four screw holes in the latch. Using a 3 mm ball-end hex driver or key, tighten until snug.

Step 3: Adjust the door latch

Close the print enclosure door. Ensure that it latches and closes securely.

If the striker cannot reach the latch, use a 3 mm ball-end hex driver or key to loosen the latch mounting screws, slide the latch slightly towards the door, tighten the screws, and test again.

If the door closes but does not latch tightly against the printer frame, open the door using the manual release cable extended from the latch. Use a 3 mm ball-end hex driver or key to loosen the latch mounting screws, slide the latch slightly away from the door, tighten the screws, and test again.

Replacing the latch striker

Overview: Replace the original latch striker. Start installing the new striker while removing the original one to avoid dropping the striker backplate into the door.

Step 1: Remove the lower latch striker mounting screw

If the print enclosure door is not currently open, pull on the latch's manual release cable to open it. Locate the latch striker on the inside face of the door.

Using a 2 mm hex driver, loosen and remove the lower 8 mm flat head screw securing the striker to the door. Do not remove the upper screw at this time. Removing both screws will cause the striker backplate to drop into the door.

Step 2: Loosen the upper latch striker mounting screw

Using a 2 mm hex driver, loosen but do not remove the upper 8 mm flat head screw. Twist the striker plate upwards to expose the lower screw hole.

Step 3: Begin mounting the replacement latch striker

Align one of the screw holes in the new latch striker with the exposed screw hole in the door. Thread one 8 mm flat head screw into the screw hole.

Step 4: Remove the original latch striker

Using a 2 mm hex driver, remove the upper mounting screw from the original latch striker. Set the striker aside for disposal.

Step 5: Finish mounting the replacement latch striker

Twist the new striker upwards, aligning the open screw hole in the striker with the corresponding screw hole in the door. Thread the remaining 8 mm flat head screw into the screw hole.

Tip:

Insert the screw or an extra driver into the upper screw hole in the backplate to prevent it from spinning with the striker.

Step 6: Secure the replacement striker

Confirm the striker aligns with the latch, then tighten the screw with a 2 mm hex driver until snug.

Reinstalling the hopper-side panel

Overview: After installing the new door latch and striker, reinstall the paneling on the hopper side of the printer.

Step 1: Reinstall the manual release handle

Install the new build chamber socket & cable harness

Pass the manual release cable through the hole in the filter cabinet. Reinstall the manual release handle onto its cable.

Step 2: Reconnect the interlock switch cable

Align the bottom of the hopper-side panel to the bottom of the printer and allow it to lean against you. Reconnect the interlock switch cable, labeled C033, to its receptacle. Route the cables into the cable clamp with the connector positioned below the clamp. If necessary, tuck the interlock cable slack into the side of the printer’s frame.

Step 3: Begin securing the hopper-side panel

Thread one M4 countersunk screw into each of the 10 screw holes in the hopper-side panel. Using a 2.5 mm hex driver, tighten until snug. For greatest convenience and ease of installation, thread and tighten in the following order:

Four 6.0 mm screws below the hopper, circled in red
Three 16.0 mm screws below the filter door, circled in green
Three 12.0 mm screws above the filter door, circled in blue

Step 4: Continue securing the hopper-side panel

Thread the two black 8.0 mm M4 button head screws into the screw holes circled in red in the image here. Thread the chrome 8.0 mm M4 button head screw into the screw hole circle in blue here. Using a 2.5 mm hex driver, tighten until snug.

Finalizing the repair

Overview: After installing the replacement door latch and striker, power on the printer and perform final checks.

Step 1: Power on the printer

Connect the power cable to the printer and the power supply. The printer initializes.

Step 2: Test the door latch

Close the print enclosure door and make sure it latches shut. Try unlatching the door using the touchscreen and the manual release handle in the filter cabinet. Contact Formlabs Support or your certified service provider to share the results of the procedure.