Fuse 1 generation and Fuse Sift preventative maintenance overview (36-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 36-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 9 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
- Z-motor and drive assembly (RP-FS1-ZMTR-01)

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 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 unbent or warped; 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.
Fuse 1 Generation Quartz Tubes	N/A	Quartz tubes have not been replaced within the printer lifetime.
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. Build chamber has been used for up to 1,000 hours of printing.
Fuse Sift HEPA air filter	The metal frame is unbent or warped; 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; is occluded with debris or powder.

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.
Recoater pinion and linear rail cleaning	Compacted powder in gear teeth or melted powder on linear rail after a cleaning with ethanol.	Powder found in pinion rack and along linear rail or previous reports of movement issues.
Tighten recoater hex bolts	If the recoater has deep gouges or buildup of melted powder after a cleaning with ethanol.	There are signs of recoater chatter or previous reports of recoat issues.
Replace recoater motor	N/A	Recoater motor has not been replaced within the printer lifetime.
Clean or replace flipper assemblies	Powder and debris accumulation or any unusual movement.	Movement issues after cleaning and calibration. Loose coupler on the motor.
Clean or replace quartz tube heater frame	Metal contacts for melted powder. Powder buildup after a cleaning with ethanol.	Metal contacts cannot be cleaned.
Fuse Z-drive assembly	Compacted powder on the bevel gear	Little to no movement using Motor Moves with a build chamber installed.
Build chamber lead screw lubrication	N/A	The build chamber has been used.
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.