Additive manufacturing (AM) has evolved from a prototyping technology into a powerful production process, capable of delivering functional, high-performance components at industrial scale. However, scaling AM into a reliable production tool requires more than just advances in printing hardware. An area of focus has become the development of seamless end-to-end solutions that can guarantee efficiency, consistency, and economic viability. Addressing this, the strategic collaboration between AM Solutions and EOS has resulted in a post-processing ecosystem built for the demands of modern industry.

EOS, a global leader in industrial 3D printing, and AM Solutions, a post-processing expert rooted in decades of finishing expertise, have co-developed the D1 and F1 systems — technologies engineered to integrate effortlessly with the EOS P3 polymer platform, including the recently launched EOS P3 NEXT. Furthermore, the F1 is compatible with all available EOS polymer printers. These systems go beyond mere automation of de-powdering, sieving, and powder mixing. They represent a connected, user-centric approach to digital manufacturing. By embedding operational intelligence and ease-of-use at their core, the D1 and F1 bridge the gap between high-end printing and practical, production-ready post-processing.

This collaboration is not just about machinery. It's a response to the wider industrial shift towards integrated workflows, enabling customers to scale up production without scaling complexity. The synergy between EOS's high-speed, precision-focused EOS P3 NEXT and AM Solutions' process-driven finishing systems reflects a shared vision of modular, automated manufacturing that anticipates the practical needs of users.

 

The Need for End-to-End Solutions in AM

Historically, AM was judged by the capabilities of the 3D printer alone. But as expectations evolve, stakeholders are now equally focused on what happens after the print completes. Post-processing — until recently an often overlooked bottleneck — has become critical in determining the overall viability of AM in production environments.

“Customers are no longer satisfied with achieving a good build,” says Fabian Krauß, Head of Product Management Polymer Solutions at EOS. “They expect factory-ready systems that deliver finished parts with minimal manual input. That’s exactly what our collaboration with AM Solutions is targeting. The D1 and F1 systems weren’t developed in isolation — they’re part of a broader workflow strategy that prioritises consistency, traceability, and throughput just as much as geometric freedom.”

David Soldan, Head of AM Solutions - 3D post processing technology, echoes this sentiment. “Since presenting a first development status in November last year, we have continued our intensive cooperation and made significant progress. The collaboration with EOS is extremely constructive and based on partnership. In our view, the two machine solutions will prove to be real game changers.”

By tightly coupling EOS’s exchangeable frames with an intelligent, automated post-processing chain, the partnership helps users unlock the full value of AM — from CAD to clean, repeatable parts.

 

Addressing Key Industry Challenges

For AM to fulfil its promise as a viable production technology, it must overcome several interconnected challenges. As the industry pivots from prototyping to full-scale manufacturing, expectations around efficiency, consistency, and cost-effectiveness intensify. Among the most pressing concerns are sustainability, the shortage of skilled labour, health and safety compliance, and the increasing demand for automation. These aren’t isolated issues but rather interdependent factors that must be addressed holistically to unlock AM’s full industrial potential.

Sustainability is particularly critical, with companies under pressure to reduce material waste and enhance process efficiency. Powder reuse in polymer AM remains a focal point, demanding advanced handling systems that can balance quality and reusability. At the same time, a limited pool of trained technicians makes it essential to develop systems that simplify operation without compromising performance. Health and safety is another non-negotiable aspect, especially given the risks associated with powder exposure. Automation emerges as a natural solution to many of these issues, streamlining workflows, reducing manual handling, and enabling scalable, repeatable production.

EOS and AM Solutions have shaped their collaboration around these core industry imperatives. The result is a set of intelligent, automated systems — specifically the D1 and F1 — that integrate seamlessly with the EOS P3 polymer platform, including the EOS P3 NEXT. Furthermore, the F1 is compatible with all available EOS polymer printers. These systems address sustainability through efficient powder reuse, improve safety by limiting human contact with materials, and bridge the skills gap with intuitive interfaces that require minimal training. Their joint approach reflects a broader industry shift toward connected, end-to-end ecosystems that empower manufacturers to scale AM operations responsibly and reliably.

 

Sustainability and Material Efficiency

One of the core advantages of AM is its ability to reduce material waste compared to traditional subtractive manufacturing processes. However, the challenge of efficiently reusing and recycling powder in polymer AM remains an ongoing concern.

The F1 system, developed by AM Solutions, addresses this issue directly by uniquely combining the processes of screening and mixing. The smart system ensures reproducible results by creating a high-quality blend of new and used powder with customisable mixing ratios.

Krauß highlights the significance of this advancement. “AM Solutions’ technology is a perfect complement to the EOS P3 polymer platform, including the new EOS P3 NEXT. As a result of this collaboration, our customers will have an end-to-end production solution that streamlines their production workflow and allows them to grow at their own pace.”

 

Automation the Key to Scalability

As AM moves toward higher production volumes, automation becomes a necessity rather than a luxury. Manual de-powdering and handling processes introduce inefficiencies, increase costs, and create variability in part quality.

By integrating the D1 automated de-powdering solution, EOS users benefit from a closed-loop system that reduces powder contamination and ensures a consistent processing. This innovation is particularly beneficial for industries with stringent quality requirements, such as aerospace, medical, and automotive manufacturing.

“Customers are no longer just asking about part production itself,” explains Krauß. “They want to know about the entire production chain — how it’s managed, how materials are handled, and how automation can drive down the cost per part.”

 

Health and Safety Considerations

Powder handling in AM poses significant health and safety concerns, particularly when dealing with fine polymer powders that can be hazardous when inhaled or come into contact with the skin. Traditionally, operators have had to manage powder manually, increasing the risk of exposure.

The D1 and F1 solutions reduce direct human contact with powder, creating a safer work environment. “We are really proud that we see now that we have both together created a solution for powder handling that is as convenient as possible while minimising exposure risks,” states Soldan.

 

Bridging the Skills Gap

The AM industry faces a growing skills gap, with a shortage of highly trained technicians capable of managing complex production workflows. One way to address this is by simplifying and automating processes wherever possible.

The solutions developed by EOS and AM Solutions reduce the reliance on highly skilled labour by introducing intuitive, user-friendly automation. With minimal training, operators can manage the entire workflow from printing to post-processing, increasing accessibility and reducing labour costs.

 

A Blueprint for Future Collaborations in AM

The partnership between EOS and AM Solutions represents more than just the development of two machines, it sets a precedent for how collaboration should function in the AM ecosystem. By leveraging each company’s expertise — EOS in 3D printing and AM Solutions in post-processing — the partnership is delivering real value to AM users, proving that no single company can tackle AM’s challenges alone.

Soldan summarises the importance of this collaboration. “Our combined expertise has enabled us to develop a solution whose quality and practicality could only have been achieved through close cooperation.”

This approach reflects a broader trend in the AM industry — one that emphasises integration, connectivity, and seamless workflows over isolated innovations. As AM continues its journey toward true serial production, partnerships like the one between EOS and AM Solutions will become increasingly essential.

 

Looking Ahead

At Formnext 2024, the D1 and F1 were presented for the first time in their early development stage, offering visitors valuable insights into the future of automated AM post-processing. The systems are currently deployed at selected beta partners for evaluation under real-world conditions. With the ability to de-powder, sieve, and mix powder in a fully integrated manner, these systems mark a significant milestone in AM’s evolution.

By developing solutions that address sustainability, automation, health and safety, and workforce challenges, EOS and AM Solutions are not just advancing post-processing, they are shaping the future of industrial AM. Their collaboration underscores the reality that end-to-end solutions are the key to unlocking AM’s full potential as a scalable production technology.

As Krauß succinctly puts it, “This is about more than just improving post-processing. It’s about redefining how AM production workflows function — from start to finish.”

With this level of innovation and strategic collaboration, the path toward AM’s integration into mainstream manufacturing has never been clearer.