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Fuse 1 generation, Fuse Sift, and Fuse Blast preventative maintenance overview (24-month)

Fuse 1 generation, Fuse Sift, and Fuse Blast preventative maintenance overview (24-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 24-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 printer 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 motor (RP-FS1-BSTEP-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

Fuse Sift units

  • All units
    • Fuse Sift HEPA Air Filter (HF-FS1-01)
    • 150 micron sieve (SV-FS1-01)
  • 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)

Fuse Blast units

  • All units
    • Fuse Blast HEPA air filter (RP-FB-HFTR-01)
    • Dispense nozzle (RP-FB-NOZ-01)
    • Fuse Blast door window (RP-FB-WIND-01)
    • Fuse Blast Small Tumbler Basket Liner Kit (RP-FB-BLNE-01)
  • Polishing System only
    • Fuse Blast Polishing System Preventative Maintenance Kit (RP-FS1-FB-PMK-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

  1. 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. 

  1. 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.

  1. 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.

  1. 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.

  1. 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.

  1. Fuse 1 generation recoater motor

N/A

Recoater motor has not been replaced within the last year.

  1. Fuse 1 generation quartz tube heater (both voltages)

N/A

During every 24 month PM visit.

Maintenance

 

Check

Perform/Replace If

  1. 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. 

  1. Tighten recoater hex bolts

N/A

There are signs of recoater chatter or previous reports of recoat issues. 

  1. 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.

  1. Build chamber lead screw lubrication

N/A

The build chamber has been used.

  1. Build chamber print bed

Loose powder buildup and fraying felt. 

Felt is fraying or sintered powder has built up.  

  1. 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.

  • Doser valve errors or sudden powder spill during fill operations.

  1. Fuse 1 generation upper laser window

The window is free of smudges or contamination after a single cleaning with the recommended swabs.

  • Signs of thermal pad degradation are visible.

  • Single cleaning does not remove visible contaminants

  1. 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. 

Fuse Blast

 

Check

Perform/Replace If

  1. 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. 

  1. Blast gun nozzle cleaning

There are no clogs or buildup inside. 

Clean out the blast gun if needed. Inspect the nozzle for wear and replace if the inner diameter has widened.

  1. Ionizer cleaning

Debris in the ionizer tips. Visually inspect the ionizer cable for integrity and wear.

Clean as needed with a cotton swab.

  1. Media line cleaning

Line connection from nozzle to chamber wall.

Internal connections followed through the whole system. 

  1. Tumbler basket liner 

Material flaking off and worn areas

  • Loose pieces clogging the blast lines

  • Metal barrel visible through worn areas

  1. Replace door window 

N/A

Scratches or fogging are significantly reducing operation visibility. Visibility only affects manual cleaning.

  1. Water injection needle (Polishing System only)

Water hose connection area contains the needle. 

Clean out any buildup. Replace if broken.

  1. Water hose (Polishing System only)

Connection from nozzle to chamber wall. 

Replace if punctured.