Blog Archives - Fusion 3 Design https://www.fusion3design.com/category/blog/ Fusion3 3D Printers: Industrial/Commercial 3D Printers, US Made Thu, 09 Nov 2023 19:37:34 +0000 en-US hourly 1 https://wordpress.org/?v=6.6.1 https://www.fusion3design.com/wp-content/uploads/2022/11/cropped-favicon-32x32.png Blog Archives - Fusion 3 Design https://www.fusion3design.com/category/blog/ 32 32 Fusion3 is Looking to Expand the Technical Support Team https://www.fusion3design.com/fusion3-is-looking-to-expand-the-technical-support-team/ Thu, 09 Nov 2023 19:34:02 +0000 https://www.fusion3design.com/?p=7364 The post Fusion3 is Looking to Expand the Technical Support Team appeared first on Fusion 3 Design.

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Fusion3 is Looking to Expand the Technical Support Team

Fusion3 is Hiring!

At Fusion3, we’re dedicated to providing the best technical support for our EDGE 3D printers we manufacture. Our mission is to assist customers in every aspect, from answering questions to resolving issues and ensuring they get the most out of their Fusion3 equipment. We take pride in being the go-to resource for our valued customers.
We are looking to expand our support team with the role of a Technical Support Associate. This person should have a passion for 3D printing and helping people. As a Technical Support Associate at Fusion3, your role is pivotal in delivering exceptional service to our customers.

Does this should like something you would be interested in applying for? Click here for a full job description to learn more about the role and how to easily apply.

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Call for Mac F3Slic3r Beta Testers https://www.fusion3design.com/call-for-mac-f3slic3r-beta-testers/ Tue, 08 Aug 2023 15:22:15 +0000 https://www.fusion3design.com/?p=6986 The post Call for Mac F3Slic3r Beta Testers appeared first on Fusion 3 Design.

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Call for Mac F3Slic3r Beta Testers

CALLING ALL MAC USERS

We are looking for beta testers for the Mac version of F3Slic3r!  If you are a power user with your Mac and you’d like to help us beta test a Mac version of our new slicer, please reach out to us at support@fusion3design.com.  We’ll provide you with a download link and connect you with our dev team.

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Updates to our Replacement Parts Store PO Process https://www.fusion3design.com/updates-to-our-replacement-parts-store-po-process/ Wed, 12 Jul 2023 19:16:21 +0000 https://www.fusion3design.com/?p=6606 The post Updates to our Replacement Parts Store PO Process appeared first on Fusion 3 Design.

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Updates to our Replacement Parts Store PO Process

As part of our focus on process improvement and always looking for ways to make our business more efficient and better able to address our customer’s needs, we have some updates to our Replacement Parts Store PO process we need to share.

As many of you are aware, we strongly prefer customers to use credit cards in our replacement parts store to order accessories, consumables, and replacement parts.  This reduces our overhead and enables us to more quickly and accurately fulfill your orders and get your parts to you.  And this preference remains unchanged – if you can, PLEASE place orders using a credit card.

However, we know not all organizations are set up to allow this.  And those folks still need to be able to order parts from us.  As the number of POs we process has increased, we’ve identified several areas of improvement.  Our goals are to improve the speed at which we fulfill PO store orders, reduce the back-and-forth correspondence needed before the order can be processed, and improve order fulfillment accuracy.

To support these goals, we’ve revised our Store purchase order process.  Going forward, if you need to place an order for parts from our store, please follow this process so we can process your order.  Orders submitted that do not adhere to this process may not be accepted.

Read the revised process here.

To be clear, this only applies to orders for parts through our online store.  This does not apply to full printer orders, which can be placed via PO.

As always, thank you for your business and happy printing!

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Updates to our New User Training Curriculum https://www.fusion3design.com/updates-to-our-new-user-training-curriculum/ Fri, 23 Jun 2023 14:43:16 +0000 https://www.fusion3design.com/?p=6424 The post Updates to our New User Training Curriculum appeared first on Fusion 3 Design.

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Updates to our New User Training Curriculum

We’re excited to announce a major change in the way we onboard new users! 

Historically, we’ve asked new (and returning) customers to attend one of our live training sessions when they received their Fusion3 3D printer.  After using this approach for several years and collecting user feedback and support metrics, we decided there was room for improvement in how we onboard and educate our customers.

Effective immediately, we’re releasing a series of New User Training videos to replace our live training sessions.  These videos cover everything you need to know to unpackage your 3D printer, set it up, run your first print, and get familiar with our slicer and the full 3D printing workflow.

As with our live training sessions, we ask that ALL new Fusion3 customers watch these videos before using their 3D printer.  We believe this is so important that this is a prerequisite for activating your warranty and receiving support from our customer support team.  Users who attend our training sessions (or watch these videos) have an average of 40% fewer issues & questions than users who don’t in the first weeks of ownership.

To view these videos, visit this page: New User Training.  

If you have suggestions for additional topics we should cover, please drop us a note!  And as always, happy printing!

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Introducing our new slicer, F3slic3r https://www.fusion3design.com/introducing-our-new-slicer-f3slic3r/ Fri, 23 Jun 2023 14:32:49 +0000 https://www.fusion3design.com/?p=6416 The post Introducing our new slicer, F3slic3r appeared first on Fusion 3 Design.

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Introducing our new slicer, F3slic3r

 

We’re excited to announce the release of our new slicer, f3slic3r!  This is a new free and open source slicer we’ve been working on for several months.  While it’s heavily based on the excellent work by Prusa Research (Prusaslicer) and Slic3r dev teams, f3slic3r has been optimized for our printers and to give our customers an excellent user experience, and excellent quality prints!

F3slic3r is free and open source:

 

  • You do not need to purchase a license key to use the software
  • Users in secure/non-networked environments do not need to do anything special to activate/use the software
  • You can install the software on as many computers as you like without restrictions.  This makes f3slic3r ideal for classroom or other multi-user environments.

All Materials Still Supported

F3slic3r has profiles built in for all Fusion3 materials. Simply refer to our Certified Materials List to find which profile to use for your material. On the right side are three new columns that tell you what profile to use in f3slic3r for a specific material.

For more information, see our blog post on our updated Certified Materials List.

Starting today, printers purchased from Fusion3 will no longer include our REACTOR slicer.  Instead, these printers will ship with f3slic3r.  

We encourage all existing users of our EDGE 3D printer to migrate to f3slic3r as soon as they’re able. 

F400 and F410 Users

F410 users have some profiles available in f3slic3r, but not all.  We encourage F410 users to download the software and see if it has profiles available for your material.  We are adding more as quickly as we can.

F400 users will need to wait to use f3slic3r.  We don’t have profiles available for the F400 yet, but we’re working on it!  We’ll let everyone know when these are ready.  For the time being, please continue to use your current slicer.

How to Get & Use F3slic3r

For more information on f3slic3r, including links to download the installer, see our website here

For a quick 16 minute introduction to the basics of using f3slic3r, see our training video here

As time goes on, we’ll publish short videos covering intermediate and advanced topics.  So if you encounter something that is confusing or you think needs an explanation, please drop us a line!

The Plan Going Forward

Our plan is to migrate all of our users of all printers to f3slic3r over a period of time.  We will continue to provide support and assistance with REACTOR for 1 year.  After that time, we will no longer offer support for REACTOR, including questions regarding its use and license key/activation issues.

Mac Build Coming Soon!

We are working on a Mac build for f3slic3r and will have it available soon.

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Materials List Update: New Materials https://www.fusion3design.com/materials-list-update-new-materials/ Thu, 22 Jun 2023 18:51:03 +0000 https://www.fusion3design.com/?p=6407 The post Materials List Update: New Materials appeared first on Fusion 3 Design.

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Materials List Update: New Materials

We’re excited to announce another update to our Certified Materials List.  This update includes some new high-performance materials from our favorite suppliers, as well as a major update to the list structure itself.

Update to List Structure

To support the release of our new slicer, f3slic3r, we’ve added some additional information to the Certified Materials List.  On the right side are three new columns that tell you what profile to use in f3slic3r for a specific material.

Why do we need this?  Unlike in REACTOR, where every material had its own profile, f3slic3r works differently.  F3slic3r uses the concept of “family profiles”.  That means there’s one ABS profile for every ABS on our list, for example.  Family profiles make maintaining the software simpler and ensure higher accuracy of the profiles.  

 Some materials need different settings than the family profile has, and for those materials, we make a specific profile.  You can see this in the nylons category where many of those materials need their own profile.

 One final note: You’ll see the F400 profile column is blank.  We don’t yet have f3slic3r profiles done for F400 machines, so for the time being continue to use your current slicer.

Glass-Filled Alloy910 (GF-A910)

New material from Xtellar (acquired Taulman).  Variant of their highly successful Alloy910 nylon.

  • Prints with our standard Alloy910 profiles on all platforms.
  • Tighten extruder idler bar springs to ~9mm (0.36″).  (Normal gap is 0.425″)

If you use this material extensively you may see higher wear rates on the extruder and print heads; keep an eye on things.

Carbon-Fiber Alloy910 (CF-A910)

New material from Xtellar (acquired Taulman).  Variant of their highly successful Alloy910 nylon.

If you use this material extensively you may see higher wear rates on the extruder and print heads; keep an eye on things.

PCTPE

Taulman/Xtellar material.  Used to be approved but fell off the list, so we’re re-adding it.  High tensile strength semi-flexible material.  May be suitable to replace high Shore hardness (>95A) TPU/TPE in some use cases.  Compatible with all platforms.

“CarbonX” ASA+CF

3DXTech material – combines UV resistance, temperature resistance of ASA with carbon fiber for additional stiffness.

  • Prints with our standard ASA profiles on all platforms.

3DXTech is known for very high fill % in their materials.  If you experience jams or feed issues on 0.4 nozzles, consider going up to 0.6mm.

“Silk” PLA Family Profile (f3slic3r only)

Silk PLA is a relatively new take on PLA.  It has some interesting surface finish properties and is becoming increasingly popular among hobbyists.  Created by adding additives to PLA; side effects are weird flow behavior and requiring different temps.  We’ve created a generic family  profile for these materials.  We are not explicitly certifying any silk PLAs at this time so we cannot guarantee you won’t experience print issues with silk PLA. 

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New EDGE Improvement Available: Scrub Plate Spacer https://www.fusion3design.com/new-edge-improvement-available-scrub-plate-spacer/ Tue, 25 Apr 2023 13:13:26 +0000 https://www.fusion3design.com/?p=6178 The post New EDGE Improvement Available: Scrub Plate Spacer appeared first on Fusion 3 Design.

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New EDGE Improvement Available: Scrub Plate Spacer

NEW Scrub Plate Spacer

 

Here at Fusion3, we’re strong believers in continuous improvement: Our hardware, our software, and our business operations.  We’re excited to announce a hardware improvement for EDGE that will enhance your printer’s reliability and ease of use, and is a quick 5 minute installation.

The scrub plate spacer is a new part that is installed under the scrub plate, on the bed assembly.  This part replaces the stack of washers and washer retention o-ring on each screw.  We recommend all EDGE users upgrade at your earliest convenience, even if you’re not currently having any issues with your nozzle offset calibration.

The scrub plate spacer has a few key advantages:

 

Easier Maintenance: It’s easier to change the scrub pad, since now you don’t have to keep washers stacked on the screws that hold the scrub plate down.

Improved Performance: Using the scrub plate spacer makes the nozzle offset calibration more consistent.  We’ve removed compliance or flex from the system, made the scrub plate height more consistent, and better supported the scrub plate so it can’t tilt when force is applied during probing.  This means you will experience fewer re-probes during nozzle offset calibration, and more consistent first layer heights on your prints.

How to Get It

For EDGE printers with serial numbers higher than E10313, your printer comes with this part already installed.

For printers earlier than this, the scrub plate spacer is available in our store here. 

How to Install It

Please see our detailed installation instructions here. 

If you have additional questions about this change, or need help installing it, please reach out to our support team.  As always, thank you for your business, and happy printing!

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F410 Customer Training Class https://www.fusion3design.com/fusion3-f410-recorded-training-april-2021/ Sun, 02 May 2021 12:56:21 +0000 https://www.fusion3design.com/?p=1757 The post F410 Customer Training Class appeared first on Fusion 3 Design.

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F410 Customer Training Class

To START the video, please click the arrow in the video player.

To watch the video in FULLSCREEN, please click on the outline of the box in the lower right hand corner of the player window.

Should you have any QUESTIONS from the training class, please send them to support@fusion3design.com and we will promptly respond.

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5 Engineering Grade Plastics To Replace PLA https://www.fusion3design.com/5-engineering-grade-plastics-to-replace-pla/ Wed, 31 Mar 2021 15:53:53 +0000 https://www.fusion3design.com/?p=2279 The post 5 Engineering Grade Plastics To Replace PLA appeared first on Fusion 3 Design.

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5 Engineering Grade Plastics To Replace PLA

UNDERSTANDING PLA’S LIMITATIONS

If you have never used a 3D printer, or only have only used an inexpensive consumer 3D printer, you may think that PLA is the most common and possibly best 3D printing plastic to use.

PLA is a common and popular 3D printing plastic derived from renewable resources.

However, while PLA is strong and rigid, it has few benefits other than aesthetics.

PLA is quite brittle, susceptible to humidity (hydrophobic) and can shatter easily. Also, its glass transition temperature, or the temperature at which it softens, is quite low and will distort or melt in a car on a hot day.

PLA’s popularity mostly stems from the fact that PLA is very inexpensive and does not require any additional heat to ensure good layer adhesion.

With the growing number of inexpensive, consumer 3D printers, which are not enclosed, PLA is the go-to material of choice for these customers.

Two identical PLA parts with maximum infill. One shows the heat distortion from being left in a car on a hot summer’s day. (Source: Reddit)

WHY CONSIDER OTHER MATERIALS BESIDES PLA?

Now that you own (or are considering purchasing) a Fusion3 3D printer, you have the ability to print large parts quickly using higher strength, higher temperature materials with features not found on most 3D printers.

MULTI-ZONE HEATED PRINT BED

The Fusion3 EDGE 3D printer’s large 14″x14″x14.5″, multi-zone heated bed heats up to 145*C and ensures proper bed adhesion for all 3D printing materials.

LARGE ENCLOSED 3D PRINT AREA

Every Fusion3 3D Printer has an enclosed print area and multi-zone heated bed provide a stable 45*C to 70*C environment, ensuring excellent print results for high-temperature, engineering-grade materials including Polycarbonate, ABS and Nylon.

OPTIMIZED PRINT SETTINGS

Fusion3’s testing & certification process ensures our customers can successfully print the widest variety of materials for 3D printing ‘out of the box’. We publish optimized settings within our REACTOR 3D printing software.

DON’T BELIEVE THE HYPE AROUND ‘SOLUBLE SUPPORT’

Our 3D printers do not require the use of messy, difficult to use, soluble support material, requiring time and effort to wash off.

Soluble support materials are certainly valuable if your part requires ‘perfect’ surface quality or has internal chambers. However, soluble materials on the ‘open’ market are very experimental, do not work well with higher temperature materials like ABS/ASA, Nylons, and Polycarbonate, susceptible to the humidity in the air. In short, they are not reliable enough for commercial use and do not warrant the performance impact to add a second print head.

Fusion3 3D printers utilize “Breakway Supports”. If you’ve only used PLA, you may think poorly of this method as PLA is brittle making these support structures difficult to break off.

Breakaway supports with the materials listed below come off easily, leaving surprisingly clean surfaces.

A 3D printed part in ABS, showing real-time removal of breakaway supports (less than 10 seconds) and a very clean finish underneath.

FIVE (5) ALTERNATIVES TO PLA THAT YOU SHOULD CONSIDER
3D PRINTING ON YOUR FUSION3 3D PRINTER

Let’s open your eyes to 5 engineering-grade materials that print better and have greater utility than PLA with your Fusion3 F410 3D printer

ABS

ABS is a strong, engineering-grade thermoplastic that provides great resistance to abrasion, heat and impact. ABS provides some chemical resistance and is somewhat rigid. When 3D printed provides dimensional stability and has hard surface.

Cost: ABS is inexpensive (approx.$20-$30 per kilogram from quality suppliers).

Uses: ABS is well suited for a variety of 3D printed parts that require strength and durability, with rigidity, at a low cost. This could be anything from hardware brackets, to assembly fixtures to charging docks to radio housings.

Oil Filter Wrench Funnel 3d printed on the Fusion3 F410 in ABS

ASA

ASA is chemically similar to ABS but engineered for outdoor use. Like ABS, it too provides great resistance to abrasion, heat and impact. ASA has excellent dimensional stability and hardness. ASA, however, provides superior resistance to UV exposure and is somewhat chemical resistant.

Cost: ASA is more expensive than ABS (approx.$35-$45 per kilogram from quality suppliers).

Uses: You’ll look to use ASA instead of ABS for high-strength durable outdoor plastic items. Anything from outdoor furniture, mounting brackets, protective housings, and decorative items.

Outdoor antenna mount printed in ASA, taking advantage of the material’s weather and UV resistance

NYLON

Nylon, is the common name for a group of plastics called, and come in different variations, of which the most common are Nylon 12, Nylon 6 and Nylon 6-6. Nylon is a very durable material that exhibits a great strength to flexibility ratio and demonstrates excellent impact resistance. You will find that different formulations of Nylon will have excellent wear resistance, resistance to chemicals or UV radiation, and even rated as safe for food handling or medical use.

Cost: Nylons are more expensive than other materials and can range from $45 per KG for generic Nylons to over $90 per KG for unique branded formulations.

Uses: Nylon is best suited for 3D printed items that can handle friction such as gears, belts and handles. Also, items that will not scratch other items, such as assembly fixtures or Prosthetics, are well suited for Nylon. The flexibility offered by Nylon make it well suited for cases, enclosures, and robotic, mechanical and other functional parts.

Special Handling: Nylon, due to its hygroscopic nature, requires special handling with FDM/FFF 3D printing to ensure that it does not absorb humidity during and after 3D printing prior to re-use.

Set of Four Small Gears Printed in Taulman3D Alloy 910 Nylon on the Fusion3 F410 3D Printer

CARBON FIBER, FIBERGLASS & KEVLAR REINFORCED COMPOSITES

In recent years, we have seen a trend towards composite plastics reinforced with carbon fiber, fiberglass and Kevlar. The base plastic could range from any 3D printable plastic, including ABS, Nylons, Polycarbonate as well as PLA and PETG.

The addition of these reinforced materials, in small bits or commonly called “chopped” fibers, modifies the base plastic and provide additional benefits.

Structural Stress: The fibers absorb some of the structural stress within the printed part, enhancing the capabilities of the base material.

Stiffness & Dimensional Stability: By adding fibers, you shore up the part, adding additional stiffness and providing stability to the shape and dimensions of the part.

Thermal Properties: The addition of fibers improve the thermal stability of the base material, often upgrading the useful operating temperatures of the base material.

Different manufacturers will vary the size and percentage of the chopped fibers in the formulation of their filament to achieve different performance characteristics. Smaller fibers at a lower percentage will achieve a better visual quality, while sacrificing the performance characteristics mentioned above. Larger fibers at a higher percentage will result in a coarser finish with a less accurate part, but achieve higher potential theoretical material performance. Also, larger fibers may result in higher chance of print head jams and require use of a larger print head / nozzle.

Specific benefits of each material include:

CARBON FIBER

Carbon fiber reinforced 3D printer filaments increase the stiffness and strength of the base material and will decrease shrinkage of your part. Good for light weight and load bearing items.

FIBERGLASS

Fiberglass reinforced 3D printer filaments are exceptionally stiff and strong, but not brittle and provide extremely high thermal resistance

KEVLAR

Kevlar reinforced 3D printer filaments provides strength like other fibers, but still allows for some amount of flex and bend.

POLYCARBONATE

Polycarbonate has the highest strength, impact resistance and temperature resistance of any material that can be 3D printed below 300*C. These factors make it, on paper, an ideal material for Fusion3 engineering focused customers.

However, Polycarbonate, is not the easiest material to print. Developed for injection molding, Polycarbonate prefers to be 3D printed in very high temperature environments. Without a very high temperature (greater than 90*C) at sizes over 3”x3”x3” in size, a polycarbonate part may exhibit significant warping and curling.

The good news is that there are hybrid versions of polycarbonate, most notably, PC+PBT or commonly referred to as “PC+” which maintains most of polycarbonate’s traits while making Polycarbonate much easier to 3D print.

Cost: Polycarbonate will range from $30 to $60 per kilogram and PC+PBT from $45 to $55 per kilogram.

Uses: Polycarbonate has many uses for a wide variety of applications. PC is a good electrical insulator so you might find it used for electrical components. Its optical clarity, high strength and high heat tolerance make it useful for medical devices and manufacturing tooling.

Milling Fixture 3D Printed on the Fusion3 F410 in Polycarbonate

Are you ready for a high-performance 3D printer that prints so much more than plain old PLA?

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Customer Update: 8/6/2020 https://www.fusion3design.com/coronavirus-update-2020-03-12/ Thu, 12 Mar 2020 12:17:07 +0000 https://www.fusion3design.com/?p=1649 The post Customer Update: 8/6/2020 appeared first on Fusion 3 Design.

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Customer Update: 8/6/2020

Dear Fusion3 Customers, Prospects, and Business Partners;

So much has transpired around the world this year, socially and economically as a result of the pandemic. Its impacts are being felt in families impacted by the illness as well as by the economic impacts of shutdowns to assist in slowing the spread of COVID19.

PREPAREDNESS

Fusion3 was aware early on of the potential of a pandemic and its impact on the world economy and took steps to protect our business (and customers), especially in our role as an essential business as part of our country’s manufacturing infrastructure.

PRODUCTION CAPACITY

Our Greensboro, NC production facility, is running with no interruption.

Over three years ago, we decided to keep our supply chain close and source very few parts from overseas. Two months ago, with the prospect of the pandemic approaching, we made a point to secure inventory of critical components that would last us through the end of 2020 if needed.

STAFFING

We have an incredible, high-performing team here at Fusion3 and are taking every reasonable precaution to protect their welfare.

Those employees in roles that do not require their physical presence in our facilities are working from home (our sales & technical support teams, for example). Customers should not notice any difference in the quality of service and professionalism of our staff.

Our factory production staff have a number of precautions in place to ensure their safety, including required hygiene, sanitation across all steps of the manufacturing process, and increasing social distance when employees are working together as well as split shifts.

LEAD TIMES

Thanks to the hard work of our team to ensure business continuity, increased demand from customers, and our designation as an essential manufacturer / supplier, we are currently at a 3 day lead time and often we can ship WITHIN 1 BUSINESS DAY WITHIN RECEIVING PAYMENT OR A VALID PURCHASE ORDER.

Please note this may vary dramatically as we continue to see surges of orders that cannot be predicted at the time we quote your order.

We are continually working to increase production capacity and maintain our standard 3-5 day lead time, however, we must be careful to ensure that our staff remains healthy first and foremost.

Please reach out if we can be of assistance with your 3D printing technology needs? We are one of only a handful of US companies that manufacture 3D printers within the 50 states. With the surge in on-shoring our country’s manufacturing capacity, we are ready and eager to assist your company.

Sincerely,

Chip Royce
CEO / VP Sales & Marketing
Fusion3

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