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Injection molding is the preferred method of making plastic parts. It is the fastest way to make high-quality, low-cost parts. However, injection molding is capital intensive, requiring tens, hundreds of thousands of dollars for a mold (sometimes millions of dollars for the most intricate molds) which takes many weeks or months for fabrication.

FFF (Fused Filament Fabrication), the 3D printing technology that we at Fusion3 utilize, is a fantastic technology that provides a much lower cost alternative to injection molding. However, the FFF process is slow as it puts the plastic down in a small bead, one layer at a time. FFF also often struggles to approximate the visual quality of injection molding since it is a layering technology.

Fusion3 discovered a way to utilize engineering methods, derived from automotive performance tuning, to develop a fast 3D printer (which became our patented “F-Series” motion control system). In the years since, we have built on this knowledge and expertise in printing higher temperature materials such as ABS, Nylons, and Polycarbonate in the development of our 3D printers and deliver high-performance 3D printing solutions for our business and education customers.

It is this focus on precision, speed, reliability and value that differentiates Fusion3 from our competitors. Many 3D printers can meet one or maybe two of these requirements, but only Fusion3’s 3D printers delivers on all of these, thanks to our unique technology and focus on throughput.


Validated through millions of operating hours with thousands of customers, our ‘F-Series’ platform is the foundation of our 3D printers’ class-leading performance and speed.


Fusion3 3D Printers can print filament from all major families of 3D printable plastic, including standard and hybrid formulations of these most utilized 3D printer materials:

The ‘F-Series’ platform is a variant of the ‘CoreXY’ motion control system, which combines high stiffness and a low moving mass.

As part of our question for high-performance, durability & reliability, and affordability, our F306, F400 and F410 models all used a unique Kevlar cable system that is ultralight and minimizes backlash and the stretching found with traditional rubber belts.

Our newest 3D printer, EDGE, takes the ‘F-Series’ design to a new level, employing high-quality linear rails and special fiberglass reinforced belts. The investment into these new components allowed our engineers to increase travel speeds while maintaining even higher precision and accuracy. Ultimately this means customers still experience the fastest print speeds, 20-40% faster than others in our class at standard settings, while achiving similar if not better print quality. With industry-leading accuracy and speed, Fusion3’s EDGE is the highest quality, fast 3D printer available.

3.0 Extruder

Since a Fusion3 3D printer’s motion control system is moving at a faster rate than most other 3D printers, it requires an extruder (drive system that pushes and pulls the filament) with the speed and torque to keep up.

Since our inception, Fusion3 has used our own proprietary extruder and we are now at our 3rd generation deployed for use with EDGE. The 3.0 Extruder has evolved to use a belt and metal gears (instead of nylon gears), an improved filament sensor with a dynamic timeout adjustment (for better performance with slow printing materials), a new metal spring grabber, and utilizes push-to-fit connectors for the bowden tube.

Rigid Metal Enclosure

Fusion3, since our F400, has used structurally rigid aluminum enclosures,similar to the unibody frame of a car. This provides a stable platform, eliminating vibration and ensuring fast, quality 3D prints. Also, we have found that this not only adds to the longevity to the 3D printer in harsh operating environments, but customers have also found much higher residual values for their 3D printers should they go to sell them on the open market versus our competitors.


Commercial 3D Printers

What’s the difference between a consumer and a commercial 3D printer?
The difference between a consumer and a commercial 3D printer is in the printing capability, printing speed, and the application itself. Consumer printers are much smaller and slower than commercial-grade 3D printers. Additionally, consumer 3D printers are much more limited with the choice of filaments, while their commercial counterparts can print a wide variety of materials.
What are some of commercial applications of 3D printing?

The most common commercial applications of 3D printing are:

  • Prototyping
  • Low-Volume Manufacturing
  • Supporting the Manufacturing Floor with Jigs & Assembly Fixtures
  • Metal Fabrication, including the production of low-volume Press Brakes
  • Maintaining production machinery by producing replacement parts
What is typically the price for a commercial 3D printer?

Commercial 3D printers can cost anywhere from $5,000 to $100,000. The USA-Made Fusion3 EDGE is an affordable commercial 3D printer with comparable or greater reliability, durability, and performance to other printers at similar or higher prices.

Is the Fusion3 EDGE a good 3D printer for prototyping?
Yes, the Fusion3 EDGE is a great 3D printer for prototyping. With the Fusion3 EDGE commercial 3D printer, your engineers can prototype and repeatedly test parts in much less time than using outside vendors, at great print quality, tight tolerances and high strength.
What should you look for in a commercial 3d printer?

Look for a commercial 3D printer that offers the following features:

  • Cost efficient – not only a reasonable initial capital outlay but inexpensive to operate (cost of filament & consumables) and maintain (parts & service).
  • Supports a variety of filaments – some 3D printers can only print one or two materials, limiting their utility. Look for a 3D printer that can print a wide variety of different 3D materials.
  • A large printing area – a small print area will limit the types or number of items you can print. A larger print surface not only allows for printing of larger objects but allows for large and larger print runs of one part or a set of parts, increasing the 3D printer’s utility.
  • Reliable support and extensive warranty – 3D printing is a great technology, but it is closer to a machine tool than a push button appliance. You will need great support to get the most out of a commercial 3D printer.

Want to find out how quickly your parts will print on a Fusion3 3D Printer?