New solutions, strong partnerships, and impressive real-world results

The 2025 edition of Formnext highlighted just how rapidly the AM industry continues to evolve. Record visitor numbers, new applications, and the broad spectrum of solutions on display underscored that additive manufacturing is steadily maturing into an industrial standard technology. Post-processing plays a pivotal role in making 3D printing more economical and suitable for true series production. “Despite ongoing market consolidation, we are seeing strong demand for solutions that enable cost-efficient and reproducible post-processing to move additive manufacturing forward. Automated processes not only help secure consistent quality standards but also actively counteract the skilled-labor shortage,” emphasized David Soldan, Head of AM Solutions – 3D post processing technology.

Comprehensive portfolio: Proven systems and new developments

AM Solutions showcased a clearly structured portfolio tailored to the specific requirements of additive manufacturing. Proven systems such as the S1, the S2 and the M4 were presented alongside the new M4 Basic and the M1. While the S1 system and S2 system continue to deliver the established 2-in-1 process for cleaning and surface finishing, the M4 Basic system, the M1 system and the M4 system are designed for maximum performance in surface finishing – scaled according to required throughput, from compact entry solutions to mid-range and high-volume capacities. A notable highlight was the automation solutions D1 and F1, co-developed with EOS, which have already proven their real-world readiness following intensive beta testing.

F1 and D1: Setting new standards for automated SLS processes

First time shown in 2024 as concept studies, the F1 and D1 systems have taken a decisive step toward industrial series readiness. Both solutions were tested under real production conditions as part of an extensive beta program with selected industrial customers. The beta testers were so impressed with the results that they have decided to integrate the systems permanently into their production processes.

At FORMRISE, the F1 demonstrated how precise, automated sieving and mixing of new and recycled powder – with an impressive dosing accuracy of ±2% – enhances process stability while reducing manual steps. The F1 can automate the mixing of up to 45 kg of powder per hour, enabling a throughput increase of over 30%. Its unique mixing process reduces the required proportion of new powder and significantly shortens powder dwell time, directly lowering part costs.

The D1 proved its value at a Swiss medical technology company, cutting the unpacking time of a fully loaded, high-density build job by half. In addition, the operator now only needs to load and unload the system, reducing labor requirements by up to 80%. Furthermore, the system demonstrated the ability to unpack parts that were not fully cooled, eliminating the previously required cooling and waiting time of up to ten hours.

Overall, the practical tests clearly demonstrate that both systems automate key process steps, enhance the profitability, efficiency, and reproducibility across the additive manufacturing workflow, and provide additional security through their closed-loop architecture. In doing so, they make a significant contribution to advancing fully automated and series-ready SLS production.

Vapor smoothing: Strategic partnership with LuxYours

Another highlight at Formnext was the announcement of a new strategic partnership with LuxYours, an expert in vapor smoothing and finishing 3D-printed polymer parts. As the parent company of AM Solutions, Rösler Oberflächentechnik GmbH has taken a stake in LuxYours, underscoring a clear commitment to a long-term, technologically leading collaboration.

Through this partnership, AM Solutions strengthens its portfolio with the key capability of vapor smoothing. LuxYours contributes a fully developed process with its patented Multi Purpose Smoothing (MPS) technology – a physico-chemical method for refining and finishing thermoplastic parts from a range of AM processes, including SLS, MJF, HSS, SAF, AKF, and FDM. The process stands out for its gentle yet highly controllable approach, preserving even the finest details while enabling precise smoothing of internal channels.

S1 case study: FORMRISE demonstrates impressive savings potential

At Formnext, AM Solutions – 3D post processing technology also presented a hands-on case study highlighting the significant impact of the S1 system on efficiency and resource use. The system stands out with its innovative 2-in-1 process, combining cleaning and surface finishing in a single step using only one medium.

Since 2024, FORMRISE has been operating a total of three S1 systems with impressive results:

• 60 % reduction in Polybeads consumption
• 87 % reduction in glass bead usage
• 1.6 t CO₂ savings
• 50 % shorter processing time
• Lower electricity and compressed air consumption
• Significantly reduced disposal costs
• Consistently high part quality

The case study demonstrates that the combination of thoughtful media preparation, high processing performance, and the practical 2-in-1 process not only reduces costs and resource consumption but also ensures consistently high part quality. For FORMRISE, annual savings amount to nearly €35,000, with more than half attributable to reduced air consumption alone.

The full case study is available for download here:

Update from the AutoSmooth research project: 100 % feedstock recycling marks a breakthrough in the CMF sector

In the AutoSmooth research project, AM Solutions – 3D post processing technology, Neue Materialien Bayreuth, and Headmade Materials are advancing the foundational work for an efficient, fully automated post-processing workflow for Cold Metal Fusion (CMF) parts. New findings indicate that the feedstock used is 100 % recyclable.

This opens up significant savings potential: a closed material loop drastically reduces both material and disposal costs as well as the CO₂ footprint across the entire process chain. With this dual impact of cost efficiency and sustainability, AutoSmooth sets new standards in industrial 3D metal printing. The ability to recirculate valuable raw materials almost without loss could prove to be one of the biggest breakthroughs for the economic viability of additive metal manufacturing.

Post-processing as a key driver

Formnext 2025 clearly demonstrated once again that automated post-processing is one of the most powerful levers for productivity, reproducibility, and sustainability in additive manufacturing. With new solutions, strategic partnerships, and practical results, AM Solutions – 3D post processing technology reinforces its position as a leading provider of industrial post-processing technologies.