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Fuse 1 generation, Fuse Sift, and Fuse Blast preventative maintenance overview (12-month)

Fuse 1 generation, Fuse Sift, and Fuse Blast preventative maintenance overview (12-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 12-month preventative maintenance visit to maintain peak performance of a customer’s Fuse 1 generation printer, Fuse Sift, Fuse Blast, 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 9 months. For a Fuse Blast, this schedule reflects a Fuse Blast running recommended media with listed presets 3–4 full cycles per day.

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)

Fuse Sift units

  • All units
    • Fuse Sift HEPA Air Filter (HF-FS1-01)
    • 150 micron sieve (SV-FS1-01)
  • Fuse Sift missing “Sift 1.1” sticker
    • Doser assembly (RP-FS1-SDOS-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)

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)
  • 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 Blast HEPA air filter

  • Installed for 100 hours or more of operation.

  • The felt or mesh is torn or damaged.

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

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. 

  1. Build chamber lead screw lubrication

N/A

The build chamber has been used. 

  1. Retrofit new Fuse Sift doser assembly (if applicable)

Formlabs Services will confirm if a Fuse Sift has an older revision doser assembly.

Formlabs Services confirms that an older revision doser is present and a newer assembly has been received prior to the site visit.

  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.

  • The user has reported doser valve errors or sudden powder spill during fill operations.

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. 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.