Formlabs launches Fuse X1 and reports $250M in yearly revenue

Formlabs launched the Fuse X1, a large-format selective laser sintering 3D printing system priced from $84,999, and disclosed its financial results publicly for the first time. The company reported 2025 revenues surpassing $250 million, a free cash flow margin above 10 percent, and more than two years of sustained profitability—figures that position it as one of the most commercially successful independent 3D printing companies in the market today. Customers have printed over 500 million parts on Formlabs machines across its SLA and SLS platforms.

The Fuse X1 is available for order today with deliveries starting in Q4 2026. Formlabs positioned the machine as a direct challenge to industrial powder bed fusion systems that cost significantly more, claiming a 50 percent lower cost per part and three times the throughput of comparable systems. The system features a 330 × 330 × 565 mm build volume and a packing density above 30 percent—more than double the 10–15 percent ceiling typically associated with multi-jet fusion printers. It installs in approximately one hour, fits through a standard door, and runs on single-phase power without specialized HVAC requirements.

New tech from Formlabs

Formlabs introduced two proprietary technologies with the Fuse X1. Adaptive Thermal Control manages 13 independent thermal zones across the build chamber and processes 700 times more thermal data per second than the Fuse 1+ 30W, keeping print conditions stable from the first layer to the last. Print Intelligence is an AI-powered computer vision system that uses real-time thermal imaging to monitor every layer, detect anomalies, and selectively remove affected parts from subsequent layers, which reduces material waste.

The full ecosystem includes the Fuse X1 printer and modular Build Unit, the Fuse Sift X1 for powder recovery, a vacuum conveyor for automated powder transport, and a high-capacity configuration of the Fuse Blast post-processing unit.

Customer results

Tesla used the Fuse X1 to produce end-use parts and tooling at its Giga Nevada facility. “With the increased throughput and decreased costs, Fuse X1 has completely changed our perspective on what kinds of projects our lab can support versus what we would have traditionally moved to an injection mold,” said Cody Jepson, Engineering Technician, Additive Manufacturing at Tesla Giga NV.

Radio Flyer cut prototype lead times for its Flyer Loop cargo e-bike frame from two months to a matter of days. “With Fuse X1, we can now print an entire Flyer Loop cargo ebike overnight and be gluing it together the next day,” said Agostino LoBello, Product Development Engineer at Radio Flyer.

Service bureau Autotiv Manufacturing, which operates more than 200 printers and ships 10,000 parts per week, projected a return on investment five times faster than comparable SLS systems. In the four months prior to launch, Formlabs customers printed over 30,000 parts on early-access Fuse X1 units. The Fuse X1 will make its first public appearance at the Reindustrialize Summit on June 16 in Detroit, MI. Parts printed on the Fuse X1 are also available to order through Form Now, Formlabs’ new online 3D printing service.