Fuse 1 generation and Fuse Sift preventative maintenance overview (48-month)

Formlabs SLS service plans include preventative maintenance visits for covered machines. This article outlines the tasks that authorized service technicians will perform at a 48-month preventative maintenance visit to maintain peak performance of a customer’s Fuse 1 generation printer, Fuse Sift, and build chambers. If you do not have a service plan, you can follow this article as a guide to maintain your own machine.

This schedule reflects a Fuse 1 generation and Fuse Sift that completes ~2–3 prints (or 40 printing and 2–3 extraction hours) per week. Customers who, on average, complete >3 prints per week may require maintenance visits as frequently as every 18 months.

The unit should be operational and pass all priming checks at the end of maintenance. If there are any errors or issues found during or after maintenance is completed, please contact Formlabs Support.

Recommended supplies

This list should not be considered comprehensive of all work that will be required in all cases. For preventative maintenance visits done by a technician, the service representative will consult with the customer while arranging the visit to identify any additional issues that may require attention.

For customers servicing their own machines, spare parts are available for purchase on the Formlabs Store.

Fuse 1 generation units

All units
- Replacement air intake filter (IF-FS1-01)
- Replacement air exhaust filter (EF-FS1-01)
- Recoater roller unit assembly (RP-FS1-RU-01)
- Quartz tube heater (RP-FS1-120-QT-01 or RP-FS1-230-QT-01)
- SKU is voltage-specific
- Two in each unit—replace both
Doser assembly
- Fuse 1+ 30W (RP-FS1P-DOS-01)
- Fuse 1 (RP-FS1-DOSE-01)
Required for 230 V units
- Fuse 1 only: Fuse 1 air heater assembly (RP-FS1-230-AHTR-01)

Fuse Sift units

All units
- Fuse Sift HEPA Air Filter (HF-FS1-01)
- 150 micron sieve (SV-FS1-01)
- Mixer assembly (RP-FS1-SMIX-01)
Customer using Nylon 11 CF Powder or TPU 90A Powder
- 300 micron sieve (SV-FS1-02)

Fuse 1 generation build chamber

All units
- Build chamber inner gasket (RP-FS1-VSS-01)
- Build chamber external frame gasket (RP-FS1-BG-01)
- Build chamber print bed assembly (RP-FS1-PB-01)
- Build chamber lead screw cleaning kit (RP-FS1-LSCK-01)

Checklists

Some printers may be due for all or only a few of the standard preventative maintenance procedures. Refer to the tables below for what criteria qualifies a component or subsystem that is in need of service.

Consumables

	Check	Replace If
Fuse 1 generation intake filter	The black plastic housing at the base and top are undamaged. Occluded pleats can be cleaned with basic vacuuming.	Pleats are shedding or splintering. Base does not secure to mount in the cabinet. Filter has exceeded its operating life of 1,000 print hours.
Fuse 1 generation exhaust filter	The metal frame is not bent or warped and the inward-facing gasket is intact. Occluded pleats can be cleaned with basic vacuuming.	Pleats are shedding or splintering. Inward-facing gasket no longer seals. Filter has exceeded its operating life of 1,000 print hours.
Build chamber external frame gasket and inner gasket	Both gaskets are free of any cracking, tearing, chipping or localized hardening. Excessive amounts of powder do not leak from the bottom.	There are any visible signs of damage, small or otherwise, to either or both gaskets. The build chamber has been used for up to 1,000 hours of printing.
Fuse Sift HEPA air filter	The metal frame is not bent or warped and the inward-facing gasket is intact. Occluded pleats can be cleaned with basic vacuuming.	Pleats are shedding or splintering. Inward-facing gasket no longer seals or is damaged. Filter has exceeded its operating life of 50 print extraction hours.
Fuse Sift sieve (150 or 300 micron)	The frame is unbent or undamaged and is fully secured into the sifter. Mesh is free of holes, frays or occlusion.	Mesh frame is warped or develops play when retained by all turnbuckles. Mesh has holes or stretched weaves. Mesh is occluded with debris or powder and cannot be cleaned.
Fuse 1 generation quartz tube heater (both voltages)	N/A	During every 48 month PM visit.

Maintenance

	Check	Perform/Replace If
User maintenance tasks	All user-facing maintenance tasks on the touchscreen are at 0 hours.	Any user-facing maintenance tasks that have more than 0 hours against them.
Factory reset	N/A	Always (unless user restrictions are in place)
Tighten recoater hex bolts	N/A	There are signs of recoater chatter or previous reports of recoat issues.
Recoater pinion and linear rail cleaning	Compacted powder in gear teeth. Melted powder on linear rail after a cleaning with ethanol.	Powder found in pinion rack and along linear rail. Previous reports of movement issues.
Replace recoater roller	If the recoater has deep gouges or buildup of melted powder after a cleaning with ethanol.	If the component cannot be cleaned.
Replace air heater assembly (Fuse 1 only)	N/A	If not replaced within the printer lifetime.
Replace doser assembly Fuse 1+ 30W Fuse 1	N/A	If there is powder leaking down the side of the print enclosure.
Build chamber lead screw lubrication	N/A	The build chamber has been used.
Build chamber print bed	Loose powder buildup and fraying felt.	Felt is fraying or sintered powder has built up.
Fuse Sift doser gear cleaning	Powder accumulation around the doser assembly. Occlusion of doser gear teeth with powder, powder flakes.	There are powder deposits below, around the doser assembly. The Fuse Sift has been used for >12 months. The user has reported doser valve errors or sudden powder spill during fill operations.
Replace Fuse Sift mixer assembly	N/A	Loud noises and movement issues when running the mixer
Secure build chamber piston arm screws	Print bed is level and the piston arm has no play. Customer has not been having persistent mechanical layer shifting issues.	Persistent layer shifting issues with a specific build chamber. Print bed is not level. Piston arm has play. Do not make adjustments if these symptoms are not present.