Formnext 2025 marked the tenth anniversary of the world’s largest additive manufacturing event with over 38,000 visitors looking to see what’s next for 3D printing.
The 3D Printing Industry team spent the week in Frankfurt, and provided a constant feed of news from the event. In this article we’ve gathered together almost 60 articles to provide a comprehensive review of all the news from Formnext 2025.
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With 804 exhibitors (2024: 864) spread across roughly 50,000 square meters (2024: 54,000 m²), parts of the show floor felt busier and more globally connected. Perhaps reflecting the sheer volume of machines, the desktop 3D printer companies experienced a higher footfall than the industrial enterprises.
Across the booths and stages, some manufacturers unveiled next generation metal and polymer systems, higher performance materials, smarter automation, and AI assisted workflows that hint at the future of production. Other companies were content to talk evolution rather than revolution, and increasingly the industry seems more resistant to the urge to launch a “new” product at a pace tied to the frequency of trade shows.
“Additive Manufacturing is no longer a promise for the future, but a reality in numerous industries,” said Sascha F. Wenzler, Vice President Formnext at Mesago Messe Frankfurt GmbH. “With progress, however, come new challenges. And this is exactly where Formnext comes in: It showcases solutions for the ongoing industrialization of AM, greater supply-chain flexibility, and the technology’s increased accessibility for SMEs.”
Missed out on the news? Read on below to get a complete Formnext 2025 recap of all the exhibits, and launches from AiBuild, Bambu Lab, Prusa Research, Stratasys, and others.
3D printers and system upgrades
Kicking off with 3D printers, UK-based 3D printing software developer Aibuild and robotics engineering startup Generative Machine introduced a desktop 5-axis FFF 3D printer that combines advanced motion hardware with automated process control, enabling multi-directional printing that minimizes supports and improves surface quality and part strength.
Built using Autodesk Fusion 360 and integrated with Duet3D motion control, the machine shifts from earlier hardware development to software-driven automation, adding parametric slicing and multi-axis toolpath optimization. Demonstrations planned for Formnext 2025 highlighted that this development aims to bring industrial-grade geometric freedom to smaller users.
From East Asia, Shanghai-based 3D printer manufacturer UnionTech introduced two new industrial SLA systems, the RSPro800 X and RA900, expanding its end-to-end offering for automotive prototyping, investment casting, and tyre-mould production. Described as the industry’s first four-laser large-format SLA printer, The RSPro800 X delivers up to 60% faster printing, ±0.1 mm accuracy, and an 800 × 800 × 550 mm build volume, supported by UT-ONE digital workflows.
The RA900 targets tyre-mould manufacturing with a 950 × 550 × 400 mm build area, Ra ≤3.5 µm surfaces, and production cycles reduced to 2–4 days. Live demonstrations showcased accelerated workflows and scalable digital manufacturing.
The new PROline metal AM system from One Click Metal was showcased at the tradeshow, demonstrating its capabilities for customers moving from prototyping to industrial production. The platform centers on the MPRINTpro metal 3D printer with a 500 W laser enabling faster build rates, thicker layers, and processing of higher-energy materials.
Developed with Herding Filtertechnik, a key upgrade is its self-cleaning filter offering up to 500 hours of maintenance-free operation. Paired with the MPUREpro unit featuring vacuum-assisted powder handling for larger volumes, the system streamlines unpacking, sieving, and material reuse for efficient series production workflows.
Advanced machinery manufacturer DN Solutions used the DLX 450 metal 3D printer and the DVF 5000 2nd Gen machining center to demonstrate how additive and subtractive processes can operate as a unified workflow. The DLX 450 brought attention to its large 450 × 450 × 450 mm build space, multi-laser Yb fiber architecture, and 7 m/s scanning, enabling rapid production of complex metal parts.
Visitors then saw how the DVF 5000 2nd Gen with its 15,000 rpm spindle, 230 Nm torque, and 28-position Multi-AWC can take those printed components directly into high-precision finishing, showcasing DN Solutions’ vision for connected industrial manufacturing.
Additionally, the new STLR 120 by India’s amace solutions was displayed as a compact laser powder bed fusion (LPBF) system tailored for research labs, startups, and medtech developers. Offering a Ø120 × 200 mm build volume and a 400 W fiber laser, it enables rapid iteration with first builds requiring under 1 kg of powder and supports materials from AlSi10Mg to Ti-6Al-4V.
Build prep runs on Materialise Magics Print LM, while its single-phase, small-footprint design suits university environments. A demo unit is already installed at AceMicromatic International GmbH for test builds and evaluations.
German 3D printer manufacturer AIM3D showcased a new generation of pellet 3D printing technology at the event, introducing its Voxelfill slicer plug-in with Create it REAL and a High-Performance Upgrade for the ExAM 255/510 systems. Voxelfill delivered a major strength gain, cutting PETG-GF anisotropy from 56.7% to 13.5%, while Input Shaping and Extruder Pressure Control improved accuracy, edge definition, and print speeds.
The company also broadened its footprint with new U.S. installations, underscoring the efficiency of its CEM process, which offers high throughput and up to 96% lower material costs than filament-based systems.
Another German machinery manufacturer KraussMaffei debuted its new PowerPrint Flex modular robotic large-format additive manufacturing (LFAM) system designed for scalable industrial production at Formnext.
The system blends a Comau N-170 robot, a 2,500 × 2,000 mm heated print bed, and the high-output printCore 35-25 extruder, which processes materials such as PEEK, PEI, and carbon-filled polymers at up to 70 kg/h. Guided by Siemens Sinumerik One, the open architecture supports hybrid additive-subtractive workflows, enabling faster iteration and mold-free manufacturing of large, lightweight, high-accuracy components.
Israeli 3D printing company XJet expanded access to its NanoParticle Jetting (NPJ) technology with the launch of the Carmel Pro, a compact, lower-cost system debuting at the tradeshow. Designed for SMEs, research labs, and premium jewelry makers, the machine delivers the precision, density, and surface finish of larger Carmel platforms at 60–70 percent lower investment.
Its powderless ink-jetting process supports four material channels for true multi-material metal and ceramic 3D printing, while automation features, fast job changeovers, and internal ink recirculation streamline operation and reduce waste for high-value applications.
Chief Executive Officer Guy Zimmerman described the launch as “a significant milestone in democratizing access to industrial, powderless, and safe metal and ceramic additive manufacturing.”
Joining the 3D printer launches is also Austrian engineering firm and OEM Incus GmbH unveiled the Hammer Pro25, a metal 3D printer engineered to bridge prototyping and true industrial production. The printer pairs a large automated platform with the company’s Lithography-based Metal Manufacturing to maintain 25 µm resolution at scale, boosted by dual scrolling projectors for expanded build area without quality loss.
Having up to 980 cm³/hr throughput, lights-out automation, and Ra 2 µm post-sinter surfaces, it enables stable, high-volume manufacturing while reducing cost per part and accelerating time to market. Gerald Mitteramskogler, CEO of Incus, said, “With the Hammer Pro25, we enable our customers to fully leverage the advantages of additive manufacturing – especially in industries with short development cycles.”
Elsewhere, Belgian Molten Metal Deposition (MMD) technology provider ValCUN detailed new performance data for its MMD process while also introducing REMUS 1.0, a next-generation printhead built to industrialize wire-fed aluminium AM. The MMD process melts standard aluminium wire inside the printhead, cutting energy use by up to eightfold and enabling ready-to-use parts without debinding, sintering, or build-plate removal.
REMUS 1.0 extends this capability with high-throughput wire feeding, localized preheating, oxidation cleaning, and non-planar motion, supporting industrial alloys in the 6xxx and 7xxx series. Together, the process and hardware target lower cost, deployable aluminium 3D printing for applications in cooling, automotive structures, and field repair.
French industrial silicone 3D printer manufacturer Lynxter unveiled two new immersion-based modules, NEST-GEL and NEST-POWDER, for its S300X – LIQ21 | LIQ11 silicone 3D printer at the tradeshow. The plug-and-play modules use reusable gel or water-soluble powder to fully support parts during fabrication, enabling ultrathin, complex geometries, reduced post-processing, and multi-part 3D nesting.
NEST-GEL targets high-precision industrial silicone parts with a 20–80 °C heated bed, while NEST-POWDER, developed with 3Deus Dynamics, supports soft, medical-grade components. The system offers a 280 × 220 × 100 mm build volume, 0.23-1.04 mm nozzles, and 50 µm–1 mm layer heights with single or dual independent extrusion.
One of the most engaging launches came from Chinese 3D printer manufacturer Bambu Lab debuting the H2C, a desktop 3D printer designed to advance multi-material printing for professional users. Its centerpiece is the new Vortek Hotend Change system, a contactless six-hotend array that enables up to seven materials per job, expandable to 24 with AMS, without purge waste.
Hotends remember past filament assignments, automation handles calibration and compatibility checks, and a four-camera suite monitors the printing process. Under the hood, an inductive 8-second heat-up, PMSM servo extruder, sub-50 µm motion accuracy, and a 65°C actively heated chamber make the H2C a tightly engineered platform built for speed, reliability, and serious experimentation.
Also, German 3D printer manufacturer EOS launched the M4 ONYX, a metal LPBF 3D printer engineered for higher throughput and more stable, cost-efficient production. The machine’s 450 × 450 × 400 mm build area is powered by six 400 W lasers that, according to EOS, deliver 50% faster output and up to 30% lower part costs. A FLX variant with four 1 kW beam-shaping lasers targets even greater speed and geometric flexibility.
Stability upgrades such as refined gas flow, active thermal management, and Smart Fusion controls work alongside Siemens-driven Build+ software and MES/ERP APIs to streamline qualification and cut QA workloads. With more than 90% powder reuse, automated closed-loop powder handling, and sub-30-minute job swaps, the M4 ONYX arrives as a tightly integrated, production-scale platform for advanced metal applications.
EOS CEO Marie Langer said the platform reflects the company’s “commitment to empowering manufacturers worldwide,” crediting the launch to the dedication and expertise of its global engineering teams.
Pennsylvania-based 3D printer manufacturer Xact Metal arrived at the tradeshow to highlight a measured expansion of its metal 3D printing lineup, led by the XM200G µHD. The new system introduces a 25 µm laser spot and support for 5–15 µm powders, extending the XM200G platform into applications that demand finer features; its 140 × 140 × 150 mm build area can also be extended to 290 mm in Z.
Two new powders joined the ecosystem as well, with Sandvik’s Osprey MAR 55 tool steel and Equispheres’ NExP-1 non-reactive aluminum broadening material options. Xact Metal also reported continued development of the XM300G, a mid-size machine with up to four 1 kW lasers and a 300 × 300 × 400 mm build volume intended for higher-capacity workflows.
TRUMPF Additive Manufacturing, now rebranded as ATLIX, debuted two new metal 3D printers aimed at strengthening its industrial production portfolio. The TruPrint 5000 leads the lineup, offering a 500 × 500 × 400 mm build volume, four 1 kW lasers with automatic multilaser alignment, adjustable 80–200 µm spots, and double-side recoating for stable, continuous operation.
The updated TruPrint 3000 introduces a 30% larger build area at 300 × 300 × 400 mm and a dual 700 W laser setup for medium-format parts. Both systems integrate with the latest TruTops Print software, which reduces file size and accelerates data transfer for faster build preparation.
“In continuity with our legacy as TRUMPF Additive Manufacturing, our innovations all have one target: make additive manufacturing a truly industrial reality,” said Marino Ferrarese, Head of Sales and Marketing at ATLIX.
INTAMSYS introduced the FUNMAT PRO 310 APOLLO, describing it as an industrial polymer 3D printer built for PAEK-class materials and continuous production. The system combines a 450°C nozzle, 100°C chamber, and 160°C build plate with an IDEX architecture capable of speeds up to 500 mm/s, with PAEK workflows optimized at 200 mm/s.
A sealed 3 kg drying chamber supports week-long runs of hygroscopic materials, while mesh leveling, dual-extruder auto-calibration, and onboard monitoring streamline operation. Powered by INTAMSUITE NEO and INTAMQuality, the APOLLO targets strong, heat-resistant end-use components with production-grade consistency.
British extrusion systems manufacturer E3D announced its new ObXiDian 500, a major update to its abrasion-resistant nozzle line. The new series delivers at least 5× the wear resistance of the original ObXidian and is now rated for 500°C, opening the door to high-temperature polymers.
A redesigned high-flow insert splits filament into four channels, boosting thermal transfer and raising flow rates by up to 70% for faster, stronger prints. E3D also introduced a High Flow ObXiDian 500 Complete HotEnd for Bambu Lab systems, giving H2D, H2C, H2S, and P2S users a drop-in route to higher throughput and durable, continuous performance.
In other news, Colibrium Additive expanded its metal 3D printing portfolio with the commercial debut of the M Line 4 x 1 kW system, a higher-power evolution of its earlier 4 x 400 W platform. The machine delivers a 500 × 500 × 400 mm build area and four 1 kW IPG lasers, giving manufacturers the ability to print critical features with tight precision while accelerating production in less sensitive regions.
Its modular LPS-MHS architecture keeps laser processing and material handling separate, allowing parallel workflows that cut downtime and streamline powder operations. Compatible with CoCr and Ni718, the system retains full parameter continuity with earlier M Line tools, all managed through the WRX3 suite with OPC/UA data access.
Large-format 3D printer manufacturer BigRep showed how far large-format FFF can stretch, unveiling the ONE.5 with a one-cubic-meter build volume and a new PEX2 extruder delivering 40% higher flow and Twin Mode capability.
The fully automated VIIO 250 added continuous-production features such as dual 350°C SMX extruders and an Infinity Box for hands-free spool changes, while the DRYCON system introduced 180°C drying and annealing in a dual-chamber setup. A pellet-extrusion project with Massive Dimension and new PIR-based rPLA and rPETG filaments rounded out a portfolio aimed at faster, more efficient large-scale manufacturing.
Czech based 3D printer manufacturer Prusa Research and Swedish extrusion specialist Bondtech introduced the Bondtech INDX, a purpose-built multi-material toolhead upgrade for the Prusa CORE One 3D printer. The system centers on the INDX Smart Toolhead, which uses induction heating, contactless temperature sensing, and a self-adjusting dual-extrusion feeder to switch materials within seconds.
Lightweight Thin Passive Tools, mounted at 35 mm spacing, allow up to eight nozzles on a single head with minimal purge waste. Joint development across firmware, hardware, and PrusaSlicer ensures the INDX functions as a fully integrated, high-speed multi-material solution for advanced desktop users.
Farsoon Technologies introduced the HT601P-2 large-format polymer PBF system built for high-volume, continuous production. The machine offers a 600 × 600 × 600 mm build area and two 100 W CO₂ lasers, enabling up to 12 kg of parts per day at 12% nesting density.
Digital galvo scanners, multi-zone thermal control within ±3°C, and optional IR monitoring support uniform energy delivery and less than 5% mechanical variation across the platform. An interchangeable build-cartridge system streamlines job turnover, while 220°C chamber capability expands material options to PA6, PA11, PA12, PBT, and TPU for demanding industrial applications.
Elsewhere, TPM3D presented a new generation of professional SLS solutions at the tradeshow, introducing the CF200 SLS 3D printer and PPS200 powder processing station.
Designed as a closed-loop ecosystem, the system improves efficiency, part quality, and process reliability through optimized optics, thermal control, and automated calibration. The launch underscores TPM3D’s goal of lowering barriers to industrial SLS adoption while maintaining precision, scalability, and reduced total cost of ownership.
Lastly, leading CNC machine tool manufacturer DMG MORI put the spotlight on industrial-scale additive manufacturing, showcasing advances in both hybrid and PBF technologies. Its LASERTEC DED hybrid machines combine milling, turning, grinding, preheating, laser deposition welding, and 3D scanning in one setup, allowing seamless shifts between additive and subtractive steps for complex or multi-material parts.
Blue-laser capability expands processing to reflective metals, while integrated scanning enables non-contact inspection. In PBF, the LASERTEC 30 SLM 3rd Generation introduces an interchangeable build container, external plate prep, and active Z-axis compensation, all supported by up to four overlapping lasers and CELOS X with easyAM for continuous, closely monitored production.
New materials broaden industrial AM capabilities
Next up, Zetamix ceramic and metal filaments manufacturer Nanoe and nuclear materials producer Orano used the tradeshow to exhibit their new development on anti-corrosion materials for additive manufacturing, introducing two custom Zetamix filaments: 304L stainless steel and Monel 400, engineered for nuclear applications. Developed for standard FFF systems and paired with Nanoe’s sintering furnaces, the filaments support rapid prototyping and small-scale production in high-corrosion environments such as nuclear fuel electrolysis.
Leveraging Nanoe’s “Zetamix on demand” program and expertise in metals and ceramics, the partnership aims to improve turnaround times, expand design possibilities, and accelerate feasibility studies for specialized alloys in nuclear research and maintenance.
Polish metal 3D printing company AMAZEMET presented its new AI-controlled rePOWDER atomization platform at Formnext, demonstrating fully autonomous metal-powder production for materials R&D. The system’s machine-vision model evaluates melt-pool behavior every 120 ms and automatically adjusts torch position, plasma power, and feed rate to maintain optimal conditions and improve PSD consistency.
A redesigned control cabinet in the latest version adds edge-AI computing, a high-speed PLC, and integrated gas-recirculation safety. In benchmark tests with Ti-6Al-4V, AMAZEMET achieved 0.5 kg/h output during four hours of unattended operation, with planned extensions to support alloys such as NiTi and C-103 and longer autonomous runtimes.
From the 3D printing giants, 3D printer OEM Stratasys showcased new industrial AM capabilities under its “Get Serious About Additive” theme, emphasizing certified materials and repeatable production. The manufacturer displayed nearly 200 parts across its FDM, PolyJet, SAF, P3, and stereolithography platforms, highlighting new materials such as ToughONE WhiteS and P3 Silicone 25A for high-strength, flexible, and biocompatible applications.
Live demonstrations of Digital Anatomy with Addion GmbH illustrated 3D printed anatomical eye models for training in eyelid surgery, underscoring Stratasys’ focus toward reliable, end-use polymer manufacturing. Moreover, highlights included the CoatReady mode for smoother ULTEM 9085 parts on the F900, faster carbon-fiber builds on the Fortus 450mc with the Nylon 12CF T40 Tip, expanded sustainable TrueRefill materials, and new accuracy and thermal-control features for SAF and SLA systems. The company also showcased high-temperature P3 tooling materials and new accessories designed to streamline post-processing.
And US-based materials producer Aether introduced its RapidPrint filament line at Formnext 2025, positioning it as a faster route to high-performance polymer parts. The first material, RapidPrint PA6 CF10 ABX, is a PA6 reinforced with 10% carbon fiber and tuned for high melt flow, stable bonding, and speeds between 50 and 250 mm/s.
Demonstrations on the AON3D’s Hylo 3D printer showed how its melt behavior enables up to five-times faster deposition without sacrificing strength, a practical gain for defense, aerospace, and drone programs that need rapid iteration and end-use durability.
Materials producer Cubic Ink introduced a set of new photopolymers aimed at more specialized applications, among them Cubic Ink Mold 3100 VP for breakable audiology molds and Cubic Ink Dental 3000 VP for detailed thermoforming tools, alongside a heat-resistant, high-impact resin designed for orthotics.
The materials producer also broadened its rapid-tooling capabilities through a Print & Inject workflow developed with SK Industriemodell, opening the door to injection molding with polymers such as PA66 GF, PPS, and PEEK. In parallel, Cubic Ink scaled UV-curing resin production in the US with ALTANA, a move intended to strengthen supply for industrial users.
3D printing materials company Kexcelled expanded its materials portfolio with new sustainable and high-performance materials. Highlights included the Eco-Aesthetic PLA Filament Series made with 10% recycled coffee, tea, or bamboo waste, combining natural aesthetics with a subtle aroma during printing.
The company also introduced new elastomer materials including K9 PEBA 90A and two K8 TPU variants, addressing professional needs for flexibility, durability, and refined surface quality.
New software platforms strengthen digital AM workflows
Advancing the software focus, Stratasys introduced the iAM Marketplace, an independent, hardware-agnostic platform that consolidates polymer AM materials, engineering services, and certified products. Designed as a centralized hub, it brings together offerings from brands such as iSQUARED, Forward AM, and Nexa3D to simplify sourcing across diverse hardware systems.
The platform marks a strategic expansion beyond proprietary ecosystems, supporting broader material compatibility, streamlined procurement, and increased supply resilience. Visitors explored the new ecosystem and its integration with Stratasys technologies at Hall 11.1, Booth C11.
“The launch of iAM Marketplace is a bold step forward in our materials strategy,” said Yoav Zeif, CEO of Stratasys. “It provides all manufacturers with a broad portfolio of quality-certified materials, machines, and expertise, enabling faster innovation and stronger supply resilience.
Additionally, Caracol unveiled the newest Eidos Manufacturing Software Suite, adding AI-driven sensing, expanded AM and post-processing steps, and more autonomous end-to-end workflows. Eidos Builder now connects slicing, simulation, scanning, and milling, while Eidos Nexus introduces AI Control for adaptive machine operation.
Demonstrations featured the Heron AM and Vipra AM platforms and large-format parts produced with partners such as Alstom, NP Aerospace, UK’s Digital Manufacturing Center, JOME, and CPC Group, including a 120-hour printed catamaran created with V2 Boats.
Formnext also saw Iceland-based software company Euler officially launch its real-time AI defect-detection software for LPBF and SLS, following a successful paid pilot program. The company showcased hardware-free monitoring that analyzes live camera data and has demonstrated a 77% reduction in failed-build downtime.
Co-led by Frumtak Ventures and Kvanted, its recent €2 million seed round is accelerating commercialization, patent activity, and ecosystem integrations. At the event, Euler also announced new partnerships with Autodesk and Scanlab.
Technology and consulting company Qualified AM exhibited its new QamX software, a modular system that enables streamlining AM qualification by integrating compliance, risk assessment, and supplier traceability into a single auditable workflow. The platform unifies documentation for standards such as ISO 9001, AS9100, and FDA 21 CFR Part 820, reducing qualification cycles by up to twentyfold.
Modules including QamX Cert, QamX SCM, QamX QMS, and QamX RISK synchronize data across teams, automating SOPs, pFMEA analyses, and supplier management to streamline validation for aerospace, medical, energy, and semiconductor production environments.
Belgian 3D printing service bureau Materialise rolled out a trio of new CO-AM platforms, Professional, NPI, and Enterprise, each powered by the newly introduced CO-AM Brix and CO-AM Build Platform. The upgrades bring sharper automation, tighter traceability, and easier qualification into AM workflows, from high-mix production to full multi-site execution.
A next-generation Build Processor framework adds open, modular integration for OEM tools and custom strategies. It is a clear signal that Materialise is continuing to advance interoperable, manufacturing-first AM software, finally giving users workflow control that feels industrial rather than experimental.
Luxembourg-based 3D scanner developer Artec 3D introduced Artec Studio Lite, a streamlined take on its professional 3D data-processing platform. The software leans on AI-powered photogrammetry to turn photos or videos into accurate 3D models, removing the need for dedicated scanning hardware.
Much of the core toolset from Artec Studio Pro remains, including mesh editing, measurement analysis, multi-camera merging, and artifact cleanup, while automated workflows and scale-bar support simplify reconstruction and real-world sizing. Designed to handle challenging surfaces and limited imagery, Studio Lite offers designers, educators, and small teams a more accessible route into reliable 3D capture and model preparation.
Nikon SLM Solutions partnered with Swedish visualization and analytics software company Interspectral to deliver an integrated quality-assurance workflow that ties AM Explorer directly into Nikon SLM Solutions machines. Exhibited at Formnext, the setup merges machine logs, sensor data, simulations, and CT scans into a single digital thread, using AI analytics to spot deviations and trace root causes.
When paired with Nikon’s open-architecture, multi-laser systems, the platform enables real-time process benchmarking and stability validation. Early adopters such as GKN Aerospace report improved traceability and reduced variability, positioning the integration as a practical tool for scaling AM into certified production.
“AM Explorer enhances our manufacturing process by automating complex workflows and ensuring robust quality assurance,” said Martin Thordén, Vice President at GKN Aerospace Sweden. “It supports our goal of scaling AM production while maintaining stringent aerospace industry standards.”
UK-based metal 3D printing company Wayland Additive announced that its Calibur3 NeuBeam system is now integrated into the Autodesk Fusion machine library, giving users a unified design-to-print workflow for electron beam PBF. Engineers can handle design edits, support strategies, build preparation, and slicing directly in Fusion with parameters tuned for NeuBeam, eliminating the fragmented software stacks that often slow PBF-EB adoption.
The new machine profile runs on both Windows and macOS, marking the first time Mac users can complete full Calibur3 build setups. Wayland says the collaboration boosts productivity and lowers barriers for aerospace, medical, and industrial metal AM workflows.
Montreal-based AON3D introduced a physics-driven G-code post-processing module that accelerates material-extrusion 3D printing by up to 54% by modeling each polymer’s rheology and thermal behavior. The system predicts heat buildup and dissipation within a part and dynamically adjusts deposition speed to avoid melt fracture, deformation, or weakened welds, enabling faster printing without compromising quality.
Internal tests cut a 24-hour ABS build to 11 hours. Integrated into the Hylo and Basis platform, the tool pairs high-temperature hardware with automated parameter tuning and in-situ defect detection for more efficient, lower-overhead production.
Berlin-based software developer trinckle showcased its Additive App Suite, a set of design automation tools for additive manufacturing. The platform enables engineers to create complex, print-ready designs in minutes without advanced CAD skills.
Through guided, application-driven workflows aligned with real industrial processes, the suite connects DfAM principles with production needs to accelerate design cycles, reduce costs, and scale additive manufacturing more efficiently.
Strategic acquisitions and partnerships reshape the AM landscape
Followed by new business deals, cleaning and surface finishing systems manufacturer DyeMansion’s presence at Formnext 2025 highlighted the successful integration of Munich company ASM and its VX1 vapor smoothing system into the company’s Print-to-Product workflow. Building on their 2024 sales partnership, the acquisition expands DyeMansion’s portfolio to fully cover entry-level, mid-range, and industrial polymer surface-finishing needs.
Already adopted by 50+ users, the compact, sustainable-solvent VX1 now sits alongside the Powerfuse S Manual and Automatic systems, giving DyeMansion the industry’s most comprehensive vapor-smoothing lineup. The live VX1 demonstrations at the show provided visitors with a clear view of the expanded capabilities now available.
AltForm, the newly rebranded successor to Prima Additive, introduced its expanded laser-manufacturing portfolio under Sodick’s ownership. The company premiered its Print 300 and Print 400 Series PBF systems, adding modular build chambers, stabilized gas flow, refined thermal control, and coordinated multi-laser operation, all tied into an upgraded powder-handling ecosystem.
A Print Genius 300 ran live with automated chamber extraction and a low-maintenance passivation-based filtration module. AltForm also rolled out a unified AI-driven software suite for monitoring, fleet management, and traceability, and demonstrated its modular ZENIT robotic cell for Wire DED and interchangeable laser processes.
Metal 3D printer manufacturer Nikon SLM Solutions and Additive Assurance unveiled a major monitoring breakthrough at Formnext, integrating AMiRIS Inside into the NXG platform to deliver the first near-infrared optical tomography system capable of observing all 12 lasers simultaneously in a production-scale metal 3D printer.
The system provides full-field, real-time melt-pool and layer analysis, improving consistency, traceability, and confidence for large multi-laser builds. According to the company, the integration is a step toward certifiable serial production in aerospace, defense, and energy applications.
HP Additive Manufacturing Solutions outlined a broad push toward more scalable industrial 3D printing, introducing new materials, ecosystem partnerships, and upcoming filament systems alongside updated MJF workflows. A key highlight was HP 3D HR PA 11 Gen2, a polymer offering up to 80% powder reuse and up to 40% lower variable part costs, supporting HP’s target of reducing overall cost per part by 20%.
On the metal side, OptiPowder Ni718 is now qualified for the Metal Jet S100 through partnerships with Continuum Powders and INDO-MIM, while M247LC is advancing with Continuum Powders and TECNALIA, and expanded copper applications are being developed with GKN Powder Metallurgy. HP also previewed its IF 600HT and IF 1000 XL filament printers, signaling an expanded role in high-temperature and large-format polymer production.
Another partnership was announced by Stratasys includes the 3D printer OEM working with Tritone Technologies to fold metal and ceramic production into its broader AM offering, giving customers a clearer path to multi-material manufacturing without juggling multiple vendors. As part of the deal, Stratasys has taken a minority stake in Tritone and set up a phased commercial agreement to align sales channels and reseller support.
The partnership centers on Tritone’s MoldJet powder-free process for high-throughput, industrial-grade metal and ceramic parts, known for its dense output, quick material changeovers, and ability to produce varied geometries in a single batch.
Ceramic AM enters true serial production across medical and industrial sectors
On the medical front, Austrian ceramic 3D printing specialist Lithoz showcased how ceramic AM has fully transitioned into reliable, industrial-scale production. Across aerospace, semiconductors, medical devices, and premium consumer goods, the company showed how its LCM technology and global Ceramic 3D Factory network are enabling real serial manufacturing.
Highlights included the CeraFab System S320 running a full plate of 46 turbine-blade casting cores, reflecting work at Safran Aircraft Engines, alongside Plasway-designed ALD rings produced by Alumina Systems and high-volume gas injectors from Bosch Advanced Ceramics.
Adding to that, ATZ patient-specific earmoulds created by OC GmbH and CADdent, and the award-winning Thales VORO cartridge from HiFiction AG and Steinbach AG, reinforced how ceramic AM now delivers scalable precision with both functional and aesthetic impact.
Johannes Homa, Lithoz CEO said, “This concerted focus on premiering real-world components successfully scaled to industrial level on Lithoz CeraFab printers is our manifesto for serial production in ceramic 3D printing.”
AM’s certification infrastructure expands
At Formnext 2025, amsight and Qualified AM presented their new whitepaper, Quality Management and Certification in Additive Manufacturing, offering a detailed technical guide to establishing reproducible and compliant AM workflows. The publication outlines key standards such as ISO/ASTM 52920, 52930, and 52954, along with step-by-step certification methods covering risk analysis, process qualification, and audit readiness.
It also highlights how QMS, MES, and data analytics tools enable full traceability and process stability. The whitepaper showcases amsight’s data-driven software and Qualified AM’s digital qualification framework as practical pathways for scalable, certified AM production. Visitors could obtain the printed edition at the joint booth.
“Certification in additive manufacturing is no longer a formality — it is a strategic enabler of reproducibility and industrial scalability,” said Dr.-Ing. Tim Wischeropp, Co-Founder and CEO of amsight.
ASTM International’s Additive Manufacturing Center of Excellence (AM CoE) outlined seven coordinated initiatives aimed at helping industry scale AM with greater confidence. In the United States, new projects with America Makes and partners including Boeing, Lockheed Martin, NASA, and Baker Hughes focus on faster, lower-cost qualification through improved in-situ monitoring and non-destructive inspection.
In the United Kingdom, the £38 million DECSAM program adds an aerospace dimension, with Airbus and a broad consortium working to boost LPBF productivity and promote circular material use. Certification efforts have also expanded, with new accreditations in Germany, Latvia, and the Philippines, while a partnership with Additive Center B.V. brings ASTM’s training and standards for semiconductor manufacturing.
Automation takes center stage in next generation post processing
Additive Manufacturing Technologies (AMT) closed out a strong year by introducing two major upgrades to its automated finishing systems portfolio. The PostPro UP removes manual powder-bed unpacking through direct build-plate loading and full DMS workflow integration.
Alongside UP, the PostPro SF2X is a compact unit that doubles processing volume while using PostPro AI to optimize vapor flow, temperature, and cycle times down to 30-45 minutes. Both systems were demonstrated at the Formnext event, highlighting AMT’s push toward fully automated, high-throughput post-processing.
On another note, DyeMansion showcased six workflow-focused developments aimed at lowering TCO and improving efficiency across its Print-to-Product chain. Key updates include the newly integrated ASM VX1 vapor-smoothing system with the largest chamber in its class, the L-RR Cartridge that reduces black-dyeing costs by up to 70%, and a redesigned Powerfuse S Loading Guide with integrated solvent recovery.
Additional upgrades include the Powerfuse Basket Max for 20% higher capacity and Powershot X IoT Integration for full runtime and performance monitoring. The new DyeMansion Campus platform supports operator training and standardized production knowledge.
“The future belongs to those who create value, not just features. Our focus is on innovations that push additive manufacturing toward greater scalability, competitiveness, and sustainability,” said Felix Ewald, CEO and Co-Founder of DyeMansion.
Having secured 50 patents for post-processing, PostProcess Technologies introduced the DEMI X 5000, positioning it as a high-throughput resin-removal system for increasingly large and complex SLA workflows. Building on the DEMI 4100, the new system tackles full-size SLA builds in 10 minutes or less, boosted by variable-speed pumps that generate multi-vortex agitation and an adjustable tilt mechanism for hard-to-reach geometries.
A non-flammable chemistry promises up to 75% lower waste-disposal costs, while a fully enclosed chamber, improved ergonomics, and automated lifting enhance safety. Supported by the AUTOMAT3D platform, the DEMI X 5000 brings repeatability and production-floor polish to scaled SLA operations.
Meanwhile, post-processing systems manufacturer Solukon brought a strongly automation-focused message, introducing a special SFM-AT800-S configuration that links automated part transport, depowdering, and a robotic finishing stage developed with Grenzebach and Yaskawa. The system demonstrated how multiple post-processing steps can operate as a coordinated workflow rather than isolated manual tasks.
Also on display was the SFM-AT350-E, the company’s most widely deployed unit, which employs ultrasonic excitation to clear powder from delicate geometries and handles parts up to 100 kg, including build plates from large metal AM systems such as the EOS M 400 and Nikon SLM 500. Solukon capped the week with a 10th-anniversary booth promotion for visitors.
Axtra3D rolls out a tightly linked SLA manufacturing platform
Moving on to platforms, high-speed SLA printer manufacturer Axtra3D unveiled Axtra Workflow, a fully integrated AM production platform that links build preparation, printing, post-processing, inspection, and traceability into one validated process. Pairing HPS printing with automated cleaning, drying, and UV plus thermal curing through Axtra.Wash and Axtra.Cure, the ecosystem reduces variability and streamlines throughput.
Axtra.Insight adds real-time analytics by collecting data from more than 155 sensors for layer-level monitoring, predictive maintenance, and compliance-ready documentation. Upgrades to the LumiaX1 v25 and Volume v25 software further refine sensing, motion control, slicing, and fleet management, enhancing repeatability and qualification readiness for industrial and regulated applications.
AI designed hypersonic hardware shows the potential of large scale metal AM
Dubai-based engineering company LEAP 71 and Farsoon Technologies showcased an AI-designed, metal 3D printed hypersonic precooler at Formnext, a 1.5-meter-tall component created using the Noyron computational engineering platform and produced on the large-format FS811M-U-8 system.
The project demonstrates how AI-driven design and industrial-scale LPBF can realize complex, high-performance geometries at unprecedented height. Developed as a technology demonstrator for air-breathing, single-stage-to-orbit concepts, the precooler highlights new possibilities for reusable, runway-launched hypersonic spacecraft.
“By combining Computational Engineering with large-scale metal Additive Manufacturing, we now have a shot at overcoming some of the most fundamental barriers to realizing that vision,” said Lin Kayser, Co-Founder of LEAP 71.
Fraunhofer IWU unveils next-generation WEAM for integrated electrical functionality
Fraunhofer Institute for Machine Tools and Forming Technology’s (IWU) latest Wire Encapsulating Additive Manufacturing system, shown at the tradeshow, enables direct embedding of electrical functions using standard alloy wires instead of conductive pastes or inks. The process prints homogeneous wires with controlled diameters and layouts, allowing tuned electrical performance, high mechanical strength, and reliable sensing or power delivery.
A continuously rotating printhead deposits conductors onto complex shapes, supporting applications such as de-icing radomes, stretchable TPU circuit boards, PFAS-free high-temperature wiring, and drone housings with integrated coils. The result is a versatile, recyclable pathway for multifunctional aerospace, automotive, and robotics components.
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Featured image shows Formnext 2025 at Messe Frankfurt, visitors arriving at the tradeshow. Photo by Michael Petch.
