Formlabs SLS Materials & Open Material Mode: Complete Australian Engineering Guide
Selecting the right Selective Laser Sintering (SLS) powder determines the mechanical strength, thermal stability, flexibility, and ongoing unit cost of your end-use parts. Formlabs offers a portfolio of production-grade thermoplastics engineered specifically for the Fuse 1+ 30W and the large-format Fuse X1, alongside an Open Material Mode for custom powder R&D.
Use this engineering reference guide to compare mechanical data sheets, check Fuse X1 material rollout timelines, and evaluate refresh-rate economics for Australian manufacturing.
Mechanical Properties Comparison Table
Compare key mechanical and thermal benchmarks across Formlabs’ core SLS powder portfolio (values reflect X/Y sintered orientation):
| Material | Ultimate Tensile Strength | Tensile Modulus | Elongation at Break (X/Y) | Flexural Strength | Heat Deflection Temp (@ 1.8 MPa) | Key Engineering Advantage |
| Nylon 12 Powder | 50 MPa | 1,850 MPa | 11% | 66 MPa | 87°C | Balanced strength, dimensional accuracy & 20% refresh rate |
| Nylon 11 Powder | 49 MPa | 1,600 MPa | 40% | 55 MPa | 46°C | High ductility, impact resistance & snap-fit endurance |
| Nylon 12 GF Powder | 38 MPa | 2,800 MPa | 4% | 56 MPa | 113°C | Enhanced stiffness & thermal stability under load |
| Nylon 11 CF Powder | 69 MPa | 5,300 MPa | 9% | 110 MPa | 178°C | Carbon-fiber reinforced rigidity & extreme heat resistance |
| TPU 90A Powder | 8.7 MPa | — (90A Shore) | 310% | — | — | Tough, tear-resistant flexible elastomer |
| Polypropylene Powder | 29 MPa | 1,640 MPa | 34% | 37 MPa | 58°C | Chemical resistance, watertightness & living hinges |
Detailed Material Breakdown & Applications
1. Nylon 12 Powder (General-Purpose Production Standard)
Nylon 12 is the workhorse thermoplastic for functional prototyping and serial end-use manufacturing. It offers high tensile strength, low moisture absorption, and superior environmental stability.
- Best Applications: Complex assemblies, electronic enclosures, brackets, jigs, and replacement industrial components.
- Cost Efficiency: On the Fuse X1, printing Nylon 12 in an inert nitrogen chamber enables a powder refresh rate as low as 20% (80% reclaimed powder to 20% fresh powder), drastically cutting per-part material costs.
2. Nylon 11 Powder (High Ductility & Impact Resistance)
A bio-based polyamide engineered for applications where parts must bend, flex, or absorb impact without brittle failure.
- Best Applications: Snap-fit enclosures, living hinges, thin-walled automotive or aerospace ducting, clips, and custom orthotics/prosthetics.
- Key Trait: 40% elongation at break (X/Y), making it far more forgiving under dynamic stress than standard Nylon 12.
3. Nylon 12 GF Powder (Glass-Filled Rigidity & Thermal Stability)
Reinforced with glass beads, Nylon 12 GF delivers significantly higher stiffness (2,800 MPa tensile modulus) and heat deflection resistance (113°C @ 1.8 MPa) compared to unfilled nylons.
- Best Applications: Structurally loaded housings, fixtures subjected to sustained mechanical stress, and thermally stressed industrial components.
4. TPU 90A Powder (Skin-Safe Flexible Elastomer)
A durable, rubber-like thermoplastic polyurethane (90A Shore hardness) offering 310% elongation at break and high tear resistance. Evaluated to ISO 10993 biocompatibility standards for skin contact.
- Best Applications: Custom industrial gaskets, seals, vibration dampeners, protective boots, robotic grippers, and wearable padding.
5. Nylon 11 CF & Polypropylene Powders (Available on Fuse 1+ 30W)
- Nylon 11 CF: Carbon-fiber reinforced powder delivering 5.3 GPa tensile modulus and 178°C HDT for lightweight aerospace, drone, and motorsport parts replacing machined aluminium.
- Polypropylene (PP): Lightweight, ductile polymer with exceptional chemical resistance and low moisture uptake for fluid-handling vessels and living hinges.
Printer Compatibility & Fuse X1 Material Rollout Roadmap
While the Fuse 1+ 30W currently supports the complete Formlabs powder library, Formlabs is rolling out validated print profiles for the Fuse X1 in staged PreForm software updates:
| Material | Fuse 1+ 30W Compatibility | Fuse X1 Availability |
| Nylon 12 Powder | Available Now | Available Now |
| Nylon 11 / Nylon 11 Pro | Available Now | Scheduled Q1 2027 |
| Nylon 12 GF Powder | Available Now | Scheduled Q2 2027 |
| TPU 90A Powder | Available Now | Scheduled Q2 2027 |
| Nylon 11 CF & Polypropylene | Available Now | Via Open Material Mode (or check PreForm updates) |
| Third-Party 1064 nm Powders | Available Now (Open Material Mode) | Available Now (Open Material Mode) |
Open Material Mode: Custom & Third-Party 1064 nm Powders
For Australian universities, CSIRO/research institutes, defence contractors, and polymer R&D teams, Formlabs offers Open Material Mode as a one-time lifetime license on both the Fuse 1+ 30W and Fuse X1.
- Full Parameter Control: Unlock PreForm Print Settings Editor controls to dial in custom laser scan speeds, bed temperatures, fill laser power, and layer thickness profiles.
- Broad Wavelength Compatibility: Print with any qualified third-party thermoplastic powder compatible with a 1064 nm Ytterbium fiber laser (including specialty ESD-safe nylons, flame-retardant blends, or experimental polymers).
Order a Material Swatch Kit or Custom Benchmark Print
Before committing to a machine or production run, test Formlabs SLS materials firsthand in your own facility:
- Order a Physical Sample Part in Your Chosen Material:Upload Your CAD to the Thinglab 3D Printing Service Have your part sintered locally in Melbourne on our Formlabs Fuse systems to verify dimensional tolerances, surface finish, and mechanical strength.
- Explore the Industrial Fuse X1 Platform: View Formlabs Fuse X1 Specifications & Pricing
- Explore the Accessible Fuse 1+ 30W Platform: View Formlabs Fuse 1+ 30W Specifications & Pricing
- Shop SLS Powder Cartridges & Consumables: Browse Formlabs Powders on the Thinglab Store