formlabs Fuse Sift Manual
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formlabs Fuse Sift Manual

Powder recovery station for the fuse 1 (sls) 3d printer
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Summary of Contents for formlabs Fuse Sift

  • Page 1 Manual Fuse Sift...
  • Page 3 Installation and Usage Instructions Fuse Sift Powder recovery station for the Fuse 1 (SLS) 3D printer Original English instructions Read this manual carefully and keep it for future reference. January 2021 REV 01 © Formlabs...

  • Page 4: Table Of Contents

    Fuse Sift user interface . . . . . . . . . . . . . . . . . .
  • Page 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Tools and supplies .
  • Page 7 Neither Formlabs nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information that is contained herein. Notify us if you have any suggestions for improvements or amendments or have found errors in this publication.

  • Page 8: Preface

    Preface Congratulations on purchasing the Fuse Sift. On behalf of the Formlabs team, we thank you for your purchase. The Fuse Sift is the powder recovery station for the Fuse 1, a Selective Laser Sintering (SLS) 3D printer. When a print is finished, the resulting parts are buried in loose, unsintered powder and need to be extracted.
  • Page 9 Instead of a serial number, Formlabs products have a serial name, which is a unique identifier to track the history of manufacturing, sales, and repair, and to distinguish usage when connected to a network. The serial name is on the back panel of the machine in the format AdjectiveAnimal. ...

  • Page 10: Introduction

    Introduction Intended use The Fuse Sift is a commercial, precision tool intended for use in the additive manufacture of end-user supplied designs from SLS powder. The final performance characteristics of sintered SLS powder may vary according to your compliance with the instructions for use, application, operating conditions, material combined with, end use, or other factors.

  • Page 11: Technical Specifications

    Technical specifications Parameter Unit Powder recovery station Fuse Sift 3D printing technology Selective Laser Sintering (SLS) Minimum dimensions for convenient 221.1 × 122.0 × 218.0 cm | 87.1 × 48.0 × 85.8 in access (W × D × H) Powder recovery station dimensions 99.1 ×...

  • Page 12: Product Components

    Surface grate: Protective grate covering the sifter. Fresh powder hopper lid: Access point for filling the fresh powder hopper. Control panel: A touchscreen and physical controls for interfacing with the Fuse Sift. Build chamber latch: Secures the build chamber. Build chamber enclosure: Area for housing the build chamber with prints ready to be ejected.
  • Page 13 2.3.2 Control panel Touchscreen: Interactive touchscreen for controlling subsystems and settings of the Fuse Sift. Chamber bed controls: Physical controls for raising and lowering the print bed into and out of the workspace. Sifter button: Physical control for starting and stopping the sifter.
  • Page 14 Additional Fuse Sift package components Power cable: Compatible with both the Fuse Sift and the Fuse 1. Vacuum adapter cable: Adapter for connecting the vacuum directly to the Fuse Sift. Build chamber port cover: Prevents airflow through the bed port in the workspace.

  • Page 15: Fuse Sift User Interface

    Fuse Sift user interface For detailed guidance and visual assistance, visit support.formlabs.com. The Fuse Sift’s display includes a touchscreen and physical buttons for controlling the print bed height, sifter, and vacuum. The touchscreen displays system information, settings, status of the sifter, build chamber, fresh and used powder levels, and error messages. The touchscreen serves as the user interface for the powder recovery station.

  • Page 16: Safety

    Safety Read and understand this manual and its safety instructions before using the Fuse Failure to do so can result in serious injury or death. WARNING Supervise young or inexperienced users to ensure enjoyable and safe operation. The instructions contain warnings and safety information, as explained below: DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

  • Page 17: Component And Subsystem Safety

    Component and subsystem safety 3.1.1 General The Fuse Sift requires a 230 VAC (50 Hz), 7.5 A power supply (EU) or 120 VAC (60 Hz), 15 A power supply (US) for nominal operation. Unless explicitly instructed by Formlabs DANGER Support or a certified service provider, do not disassemble or tamper with the product beyond what is explicitly outlined for typical maintenance.
  • Page 18 In general, Formlabs powder is not approved for use with food, drink, or medical applications on the human body. Refer to the safety data sheet (SDS) for each specific powder as well as support.formlabs.com for more detail. 3.1.4...

  • Page 19: Personal Protective Equipment (Ppe)

    Personal protective equipment (PPE) Safe operation of the Fuse Sift can be achieved by implementing the following equipment: • Particulate filtering respiratory protection (N95 or better)
  • Page 20 DANGER electricity to conduct across additional flammable surfaces. If a localized fire develops near the Fuse Sift, e.g., inside or outside the Fuse 1, immediately take the following actions. If the fire is inside the print enclosure: 1.

  • Page 21: Preparation And Setup

    For detailed guidance and visual assistance, visit support.formlabs.com. The Fuse Sift requires a dedicated AC circuit, providing at least 7.5 A at 230 VAC (EU) or 15 A at 120 VAC (US) , as well as reliable grounding. This circuit must be separate NOTICE from other devices—including the corresponding Fuse 1, fans, vacuums, power tools,...

  • Page 22: Unboxing The Machine

    Prior to unboxing, ensure that the suitable workspace has been prepared according to section 4.1 Location and environs. The Fuse Sift is a heavy object. A two person lift is required to prevent injury and avoid damage to the machine.

  • Page 23: Accessing The Serial Name

    The serial name is a unique identifier used to track the history of manufacturing, sales, and repair. The serial name for the Fuse Sift is located on a sticker next to the A/C input on the back panel in the format AdjectiveAnimal. For a Fuse Sift, the serial name is also available on the touchscreen.

  • Page 24: Installing The Machine

    For detailed guidance and visual assistance, visit support.formlabs.com. After selecting a location for the Fuse Sift, install the accessories if you did not do so during the unboxing process: insert the sifter mesh and surface grate, connect the vacuum hose, then connect the Fuse Sift to a power source to turn on the machine.

  • Page 25: Setting Up A Network Connection

    2. Flip the breaker switch on the back of the Fuse Sift to the ON position to turn on the machine. 3. As the Fuse Sift initiates, the Formlabs logo with a progress bar appears on the touchscreen, followed by the onboarding process.

  • Page 26: Updating Firmware

    Updating firmware Formlabs regularly releases updated firmware to fix bugs and improve functionality. Download the latest firmware version for your Formlabs device with PreForm, then upload and install the firmware file on the machine. Review the firmware downloads and release notes to learn more about the improvements that come with each version’s release.
  • Page 27 The Fuse Sift is a heavy object. A two person lift is required to prevent injury and avoid damage to the machine. CAUTION Do not ship the machine with the power cartridge inserted in the drawer or mixer. Powder left inside the machine can leak during transit, which may lead to additional NOTICE fees or void the warranty.
  • Page 28 8. Extend the unit’s feet by unscrewing them from the leg until there is a gap of approximately 13 mm (0.5 in) between the top of each foot and the bottom of its respective leg. 9. Orient the tie down brackets facing diagonally inwards, hooking the brackets around the unit’s feet bolts.

  • Page 29: Recovering Powder And Filling Powder Cartridges

    Operational environment The operating temperature for the Fuse Sift is 18–26 °C (64–80 °F), with low ambient humidity. For optimal post-processing, and particularly for recovering powder, do not exceed these limits. Cooling a print For detailed guidance and visual assistance, visit support.formlabs.com.
  • Page 30 Cooling a build chamber outside of the Fuse 1 or Fuse Sift If you are unable to cool the build chamber in the Fuse 1 or Fuse Sift, you can allow the build chamber to cool in the ambient air.

  • Page 31: Unpacking A Powder Cake

    3. Place the build chamber on a heat proof surface in a safe location. 4. Allow the build chamber to cool for 30–50% of the original print time. 5. Insert the build chamber into the Fuse Sift and begin the part recovery process. Unpacking a powder cake For detailed guidance and visual assistance, visit support.formlabs.com.

  • Page 32: Filling A Powder Cartridge

    Ensure that the valve knife is fully pushed into the cartridge before removing it from the drawer, otherwise powder may leak out during mixing. 7. Slide the cartridge onto the mixer on the right side of the Fuse Sift until the locking tabs click into place around the cartridge.
  • Page 33 5.6.2 Turning off The Fuse Sift is designed to remain powered on when not in use. Flip the breaker switch on the back of the unit to the OFF position to turn off the machine completely and conserve power. When moving or storing the machine, unplug the unit from its power source in addition to flipping the breaker switch.

  • Page 34: Maintenance

    Formlabs or a certified service provider. • Fresh powder The raw printing material for the Fuse 1. Add fresh powder to the Fuse Sift to mix with recaptured powder in a powder cartridge. The level of available powder is indicated on the printer’s touchscreen.

  • Page 35: Inspection And Maintenance

    Recovering sintered nylon powder mobilizes loose powder and byproducts of SLS printing such as off-gases and laurolactam, which collect onto Fuse Sift’s sifter mesh and vent filter. In order to preserve the reliability of Fuse Sift, it is important to regularly inspect and clean affected components and assemblies.

  • Page 36: Periodic Maintenance

    Do not use compressed air or an air gun to clean the Fuse Sift’s vent, surface grate, build chamber enclosure, or any other component. Mobilizing loose powder increases CAUTION the risk of unintentional inhalation or ingestion.

  • Page 37: Vacuuming The Vent Filter

    2. Turn on the vacuum by pushing the Vac button on the control panel or by tapping the vacuum hose icon on the touchscreen. 3. Vacuum off the top of the fresh powder hopper lid (under the Fuse Sift’s hood on the right side) so used powder cannot fall inside upon opening.

  • Page 38: Intermittent Maintenance

    Be very careful not to damage the sifter mesh with the brush. 9. Place the sifter mesh back within the Fuse Sift and refasten all the turnbuckles. 10. Place the sifter grate back over the sifter mesh.
  • Page 39 1. Turn off the machine by flipping the breaker switch on the back of the unit to OFF. Unplug the power cable from the Fuse Sift. 2. Disconnect the vacuum’s hose and power cable from the Fuse Sift, then plug the vacuum directly into a mains power outlet.

  • Page 40: Cleaning The Fresh Powder

    9. Turn off the vacuum by pushing the Vac button on the control panel or by tapping the vacuum hose icon on the touchscreen. 10. Place the sifter mesh back within the Fuse Sift and refasten all the turnbuckles. 11. Place the sifter grate back over the sifter mesh.

  • Page 41: Replacing The Sifter Mesh

    1. Tap the back section of the Fuse Sift’s diagram to turn off the vent. 2. Unscrew and remove the six thumb screws that hold the filter grate in place. 3. Pull out the filter grate that sits above and around the filter.

  • Page 42: Troubleshooting

    Troubleshooting errors or abnormal activity In the case of an error or abnormal activity with the Fuse Sift, reference the following errors, causes, and proposed solutions. Complete the initial troubleshooting steps and carefully document all results.
  • Page 43 Check the mixer for obstructions. Error message The mixer is blocked by Mixer Error an obstruction. If the error persists, contact Formlabs Mixer stops running The drive belt or pulley Support or a certified service provider after a few minutes with for the mixer is loose for additional guidance.

  • Page 44: Disassembly And Repair

    Disassembly and repair All steps that involve opening the machine and/or investigating internal components should be done by skilled persons under the guidance of Formlabs Support or a WARNING certified service provider. Any damage resulting from attempting disassembly and/ or repair without prior authorization from Formlabs Support or a certified service provider is not covered by warranty.

  • Page 45: Recycling And Disposal

    Recycling of powder 9.2.1 Unsintered powder Unsintered used SLS powder can be recaptured using the Fuse Sift for use in future prints. The Fuse 1 can print with up to 70% recycled powder. Formlabs does not operate a recycling program.

  • Page 46: Index

    Index build chamber 10, 13, 14, 17, 19, 23, 25, 26, 28, part recovery 17, 33, 48 29, 31, 32, 33, 34, 38, 48, 50, 51 powder 6, 7, 10, 12, 13, 14, 15, 16, 17, 18, 20, 21, build chamber enclosure 14, 19, 25, 26, 29, 38, 22, 23, 24, 25, 26, 28, 29, 31, 33, 34, 48, 50, 51 36, 37, 38, 39, 40, 41, 42, 43, 45, 47, 48,...

  • Page 47: Glossary

    Sift and the Fuse 1 to monitor the build chamber, and differentiate one build chamber from another. Build chamber enclosure The area in the Fuse Sift for housing the build chamber with prints ready to be ejected. Build chamber port cover...
  • Page 48 Clumps of unsintered powder pass through the surface grate before being separated by the sifter mesh. Vacuum An external vacuum connects to the Fuse Sift for cleaning the Fuse 1 and Fuse Sift after use. Valve knife The valve knife is a flat plate used to close off and open the cartridge valve.

  • Page 49: Product Compliance

    Product compliance The Fuse Sift complies with the following machinery, electromagnetic, and waste safety standards: European Machinery Directive 2006/42/EC • A-Type Standards: EN ISO 12100:2010 • B-Type Standards: EN 60204-1:2018 • C-Type Standards: None Electromagnetic Compatibility (2014/30/EU) • IEC 61000-6-2 •...

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