PrintParts Scales Manhattan 3D Printing with Formlabs Fuse 1, Becoming NYC’s Largest SLS Provider

PrintParts, a 3D‑printing contract manufacturer founded in May 2016 by former injection‑molding specialist Robert Haleluk, has grown into one of New York City’s premier service bureaus by listening to its customers and scaling its operations accordingly. Working with dozens of engineering firms, PrintParts delivers everything from first‑time prototypes to production‑grade parts and has earned a reputation for reliability and rapid turnaround.

Until recently, the company struggled to meet demand for durable selective laser sintering (SLS) parts. Traditional powder‑based systems are bulky, expensive, and hard to fit into the Manhattan‑based facility, forcing PrintParts to outsource nylon and other high‑strength components.

When Formlabs released the Fuse 1, Haleluk and COO Cody Burke seized the moment. Within a month of the announcement, they installed four Fuse 1 printers and two post‑processing Sift systems, making PrintParts the largest Fuse 1 installation in the United States.

Starting Small, Scaling Up

Haleluk began PrintParts in a WeWork office with just a couple of FDM printers, but his vision was clear: “I wanted to offer 10,000 parts a week, and eventually 100,000 a month. More machines equal higher throughput.” This focus on volume drove the early adoption of small‑footprint, cost‑effective printers such as the Formlabs Form 2 and Markforged FFF models.

PrintParts’ strategy blends traditional manufacturing principles with additive‑manufacturing expertise. The company positions itself as a partner, providing design advice during prototyping and production phases and helping clients transition to mass‑production with 3D printing.

Building a 3DP Powerhouse in a Manhattan Footprint

After moving to a former stamp factory near Madison Square Park in 2018, space remained a challenge. Narrow doorways, limited elevator capacity, and the building’s age restricted the installation of larger SLS systems. According to COO Burke, “We couldn’t bring in large powder systems or produce Nylon 12 in‑house.”

Large industrial SLS machines typically cost between $150,000 and $500,000, a price point that did not justify the margin for PrintParts until the Fuse 1 arrived. The compact, affordable printer allowed the company to add four machines in a fraction of the time and cost of a single traditional system.

A Sculpteo survey of 1,900 engineering firms revealed that 72% prioritize strength when selecting a 3D‑printing technology. Historically, this meant outsourcing to expensive powder‑based systems, a burden that PrintParts avoided until the Fuse 1 made in‑house production feasible.

“The Fuse let us bring our Nylon 12 business in‑house,” says Haleluk. “The size and price were ideal, and the parts match the quality of more expensive systems. For many customers, the cost is half what they were paying before.”

The new workflow has benefited both customers and PrintParts. By offering in‑house Nylon 12 at a lower price and shorter lead time, the company has transitioned roughly 30% of its SLS clients from external vendors.

Haleluk notes that about half of his customers come with fully fleshed‑out designs, while the other half rely on PrintParts’ expertise for design input and material selection. When a part’s geometry makes FDM or resin impractical—heavy overhangs, complex lattices—PrintParts recommends SLS, adding another tool to its production toolkit.

Pursuing the Future with the Fuse 1

Haleluk and Burke view the Fuse 1 as a platform for future growth. As new materials such as PA 11 become available, they plan to expand their printer fleet while maintaining their status as the largest Fuse 1 installation nationwide. Despite limited square footage in a Manhattan high‑rise, PrintParts believes that each additional printer justifies the space with increased capacity and customer value.

“We’re aggressively pursuing the future,” says Haleluk. “We’ve invested in a robust material catalog and technology suite, partnered with great customers, and now we’re focused on delivering production‑grade parts at affordable prices with acceptable lead times.”