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Replacing the Fuse 1 generation doser gasket

Over time, the gasket that sits between the doser and the hopper trough may degrade. It may also become damaged during other repair procedures. If the doser gasket is degraded or damaged, powder may leak from the junction between the doser and hopper trough or print enclosure.

Use this guide to replace the doser gasket on a Fuse 1 generation printer.

Required supplies:

Formlabs:

Replacement Fuse 1 generation doser gasket (RP-FS1-DGSK-01)

Third-party:

2.0 mm hex driver (flat-end)
2.5 mm hex driver (flat-end)
8 mm torque driver rated to at least 1.5 N-m
8 mm box wrench (optional)
Compliant vacuum with static dissipative components, such as a Class II, Division 2 vacuum
Vacuum brush tools
Hopper vacuum attachment, to be printed in advance (optional)
Appropriate personal protective equipment (PPE) for handling the powder in the printer
Paper towels

Estimated time: 45–60 minutes, plus time to empty the powder hopper and print the hopper vacuum attachment, if needed

Preparing the workspace

Overview: Prepare the printer and a dust-free workspace for replacing the doser gasket.

Warning:

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

Step 1: Print the hopper vacuum attachment

If you have access to another 3D printer or your Fuse 1 generation printer can complete a print before servicing, print and post-process the hopper vacuum attachment. The STL file is available here.

Step 2: Prepare the workspace

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

Step 3: Empty the hopper

Insert an empty build chamber. Tap Settings > Calibration > Empty Hopper on the printer’s touchscreen. Follow the on-screen prompt on the Empty Hopper screen to transfer the powder from the hopper to the build chamber. This process may take up to an hour.

Step 4: Clean the hopper and powder troughs

Follow the instructions for cleaning the hopper and cleaning the powder troughs from the support article Cleaning all powder out of a Fuse 1 generation printer. You do not need to clean the other components of the printer to replace the doser assembly.

Step 5: 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 doser gasket

Overview: Remove the doser from your Fuse 1 generation printer, then remove the gasket from its inner face.

Step 1: Remove the doser

Uninstall the doser from your printer. Follow the steps for your specific printer type:

Step 2: Remove the doser gasket

Peel the gasket off of the inner face of the doser. Set the gasket aside for disposal.

Step 3: Wipe the doser

Use a clean paper towel to wipe away any powder that may have accumulated underneath the gasket. Ensure the surface is clean and free of debris.

Installing the replacement doser gasket

Overview: Install the replacement doser gasket on the inner face of the doser.

Step 1: Inspect the replacement doser gasket

Inspect the replacement gasket for any contamination or debris. Use a clean paper towel to wipe it clean.

Step 2: Place the replacement doser gasket on the doser

One side of the replacement gasket has adhesive pre-applied. Peel any protective layers off of the gasket and adhere it to the inner face of the doser. Make sure that the gasket does not extend into the hopper opening and that the round cutouts in the gasket sit flush against the locating pins on the doser.

Step 3: Reinstall the doser

Reinstall the doser on your printer. Follow the steps for your specific printer type:

Finalizing the repair

Overview: After replacing the doser gasket, 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 gasket

Refill the hopper. Check that no powder leaks are visible. Insert the build chamber into the printer and start a print. Again, check that no powder leaks during the print and that the doser operates normally. Contact Formlabs Support or your certified service provider to share the results of the procedure.