FUSiON S is a high-precision metal 3D printer featuring a closed powder circuit for maximum user safety and powder efficiency. It delivers additive manufacturing of precision metal parts with no direct powder contact, making it ideal for medical, dental, jewelry, and R&D applications. The system produces complex geometries with fine detail and nearly 100% density, all within a compact footprint and a safe powder handling architecture.
FUSiON S Metal 3D Printer –
Without Direct Powder Contact
Overview
The FUSiON S is a compact, fully enclosed metal 3D printer designed for precision applications in medical, dental, jewelry, and research industries. Powered by Laser Powder Bed Fusion (LPBF) technology and a 200 W fiber laser, it builds high-density metal parts layer by layer with exceptional detail and accuracy.
Engineered with safety in mind, the FUSiON S features a closed powder circuit—eliminating direct contact with loose powder throughout the printing and post-processing workflow. All material handling is contained in sealed cartridges or chambers, ensuring a clean, low-risk environment and protecting both operators and the workspace.
With a fine laser spot (~50 µm), the system delivers intricate geometries and thin-walled structures with remarkable resolution. It consistently achieves part densities over 99.9%, comparable to traditional wrought metals, making it ideal for mission-critical components.
FUSiON S also includes pre-validated print parameters for materials such as stainless steel, titanium, cobalt-chrome, and precious metals, allowing users to start printing high-quality parts immediately—without the need for extensive trial and error.
Whether you’re aiming for safety, precision, or production-grade results, the FUSiON S brings reliable metal additive manufacturing to your lab or production floor in a small, efficient footprint.
FUSiON S Cabin
Safe and Streamlined Powder Handling for Metal 3D Printing
The FUSiON S Cabin is a compact, enclosed unpacking and powder handling station designed to work seamlessly with the FUSiON S metal 3D printer. Built to support a fully closed powder circuit, the Cabin enables safe, clean, and efficient post-processing of printed parts without exposing users to loose metal powder.
Once a print is complete, the cartridge with the printed part is transferred to the FUSiON Cabin, where they can be unpacked in a sealed, inert environment. Residual powder is automatically collected and recycled, minimizing waste and maximizing material yield. This process eliminates the need for glove boxes or additional containment solutions, reducing operational complexity.
Like the printer itself, the FUSiON S Cabin was developed with small labs and production spaces in mind. Its compact footprint matches the FUSiON S, allowing both units to sit side-by-side without consuming extra floor space. The result is a streamlined, all-in-one additive manufacturing workflow that emphasizes safety, cleanliness, and ease of use—ideal for sensitive environments like medical, dental, and R&D labs.
With the FUSiON S Cabin, users benefit from:
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Sealed powder recovery and reuse to cut costs
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Hands-free powder handling to protect personnel
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Compact and portable design for tight workspaces
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Integrated workflow that reduces setup time and complexity
Together with the FUSiON S, the Cabin completes a modern, cartridge-based LPBF solution that’s as clean and efficient as it is powerful.
Key Features
Closed Powder Circuit
for Safe Operation
FUSiON S is designed “without direct powder contact” in mind. The entire powder flow is contained within a closed, inert gas environment – from the sealed material cartridges to the build chamber and unpacking station. This closed powder cycle ensures the operator never handles loose powder during printing or post-processing, dramatically improving safety and cleanliness. All unused powder is captured for recycling, resulting in high powder yield and minimal waste. By keeping the powder enclosed at all times, FUSiON S enables safe powder handling even with reactive materials like titanium and with precious metals, without requiring elaborate protective measures.
Intelligent Cartridge
System
The FUSiON S features a sealed powder cartridge system that ensures safe, clean, and efficient material handling. Simply load the cartridge inside the cabin and insert it into the printer—no direct powder contact needed. Each cartridge is tagged with material data for automatic recognition and usage tracking. Overflow powder is captured for reuse, maximizing material efficiency and reducing waste—especially valuable for expensive or precious metals. This intuitive system streamlines setup and enables fast material changeovers, making metal 3D printing easy and accessible for any operator.
High-Precision Laser Optics
for Exceptional Detail
The FUSiON S is powered by a 200 W fiber laser with ultra-fine focus and high-precision scanning optics, enabling intricate geometries and smooth surface finishes. Its ≈50 µm spot size delivers outstanding accuracy—ideal for demanding applications like dental and medical parts. Users can access and adjust parameters for optimal results across materials and layer settings. With stable optics and robust control software, the system consistently achieves >99% part density and reliable mechanical properties—all in a compact, professional-grade platform.
Closed-Loop Inert Gas System
for Reduced Consumption
The FUSiON S features a fully enclosed argon gas circuit that recirculates and purifies gas throughout the printing process. This significantly lowers gas usage— around 1 liter per minute during operation—compared to traditional open systems. An onboard filtration and purification unit ensures clean, safe operation even with reactive or hazardous powders, while reducing operating costs and supporting sustainable use in environments with limited gas availability.
Energy-Efficient Operation
on Standard Power
Designed with efficiency in mind, the FUSiON S operates on a standard 230 V AC outlet and uses low-consumption components to reduce power draw. It delivers high-performance metal 3D printing with a fraction of the energy required by larger industrial systems—saving both energy and cost. This makes it an ideal solution for labs, clinics, and research centers seeking a more sustainable manufacturing process.
Compact, All-in-One Design
for Flexible Installation
The FUSiON S offers industrial-grade metal 3D printing in a compact 600 × 600 mm footprint—ideal for labs, workshops, and space-constrained environments. With its fully integrated powder handling and filtration system, there’s no need for bulky external equipment. A 15.6″ touchscreen interface at eye level ensures ergonomic operation, and the optional unpacking station matches the printer’s size for a streamlined setup. Running on a standard single-phase power outlet, the FUSiON S is easy to install, relocate, and fit into existing facilities.
Applications
FUSiON S enables a broad range of metal additive manufacturing applications, especially where fine detail, material efficiency, or safety is paramount. Its ability to safely process both standard and specialty alloys makes it versatile across industries. Typical application areas include:
Medical Devices & Implants
Patient-specific orthopedic implants, surgical instruments, and medical tool components in biocompatible materials like titanium and cobalt-chrome. The FUSiON S can produce intricate lattices and geometries optimized for bone integration or weight reduction, which are difficult to manufacture conventionally.
Dental Restorations
High-precision production of dental crowns, bridges, partial dentures, and orthodontic devices. The printer’s fine resolution and validated cobalt-chrome and stainless steel parameters allow dental labs to fabricate restorations with excellent fit and minimal post-processing.
Jewelry & Artistic Metalwork
Custom jewelry pieces, watch components, and decorative metal art made from precious metal powders (gold, silver, platinum, etc.). The closed powder circuit is especially advantageous here – it prevents loss of expensive material and protects the operator from exposure. Designers can create intricate filigree patterns and complex shapes with confidence that the FUSiON S will reproduce them accurately in metal.
Research & Development Prototyping
Fabrication of complex prototypes, test coupons, and experimental designs in R&D settings. The open parameter access and material flexibility make FUSiON S a great tool for universities, laboratories, and R&D departments exploring new alloys or process settings. Users can safely experiment with novel or reactive powders (such as aluminum or experimental alloys) on a small scale. The printer’s compact size and relatively low power needs also suit it for research labs and educational institutions.
These examples only scratch the surface. Wherever there is a need for precise, small-to-medium sized metal parts – especially in environments that demand safe handling and efficient material use – the FUSiON S is an excellent fit. Complex tooling inserts, aerospace fuel nozzles, electronics components, and more have been successfully produced with this system.
Benefits for Target Industries
Enables safe, in-house production of implants, surgical tools, and dental restorations with certified materials like titanium and cobalt-chrome. Delivers high precision in a clean, closed-powder environment.
Gives designers the freedom to print intricate pieces in precious metals like gold and platinum with minimal waste. Ideal for custom and high-value creations.
Supports safe prototyping and experimentation with various alloys. Perfect for labs and institutions needing a compact, open-parameter metal AM system.
Brings advanced metal additive manufacturing into training programs and universities, offering students hands-on experience with future-ready technology.
Enables fast, cost-effective production of complex tools and molds. Ideal for small-batch manufacturing and one-off designs.
Each of these industries requires a balance of precision, safety, and efficiency – the FUSiON S was built to deliver exactly that. Whether it’s improving patient outcomes with custom medical implants or fostering innovation in a university lab, the FUSiON S provides tangible benefits that set it apart from conventional manufacturing or even other 3D printers in its class.
Inquire Today to Transform Your Manufacturing Process
Empower your business with safe, precise, and efficient metal 3D printing. FUSiON S is ready to elevate your additive manufacturing capabilities – from prototyping to production – all while keeping your workflow clean and your team safe. Get in touch with us today to bring this state-of-the-art metal additive manufacturing solution to your organization.