Fuse Series SLS Design Guide: Design Parts That Print Right the First Time

Get proven design dimensions, orientation tips, material-specific guidance, and real-world best practices for the Formlabs Fuse Series.

What This Guide Covers

• ● Design pins, holes, walls, and text features that print cleanly.
• Apply correct clearances for assemblies and moving parts.
• Optimize part orientation to improve strength and surface finish.
• Reduce warping by managing thickness, stress, and aspect ratios.
• Design internal cavities and lattices for effective powder removal.

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Material-Specific Design Considerations

TNot all SLS materials behave the same way. The guide breaks down how design rules change depending on the powder you are using.

Minimum pin and hole diameters,  supported and unsupported wall thicknesses, engraved and embossed text requirements, escape hole sizing for enclosed cavities, Assembly tolerances, and integrated clearances.

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