FELIX 3D Printers Redefines Industrial Additive Manufacturing with New Pro XL 3.1 & Pro XXL Systems at Formnext 2025

In the dynamic world of industrial 3D printing, the pursuit of scale and standardization often dictates innovation. However, since its inception in 2011, FELIX 3D Printers, a distinguished Dutch manufacturer, has carved out a unique niche by championing a different ethos: adaptability through modularity. This foundational principle has enabled FELIX to develop bespoke 3D printing solutions alongside its standard product lines, serving a diverse array of demanding sectors including manufacturing, healthcare, bioprinting, and food production. Thanks to its pioneering modular printer architecture, FELIX 3D Printers possesses the unparalleled ability to conceptualize and deliver customized, application-specific printers with remarkable speed and efficiency. Now, as the industry converges at Formnext 2025, FELIX 3D Printers is poised to extend this very principle of adaptability and modularity directly to the factory floor, unveiling the final prototypes of two groundbreaking industrial systems: the Pro XL 3.1 and the Pro XXL.

These two revolutionary printers are meticulously engineered upon FELIX 3D Printers’ extensively proven modular platform. They embody a perfect synergy of high-speed performance, unwavering reliability, and a robust, low-maintenance design, purpose-built for the rigorous demands of industrial environments. Complementing these cutting-edge systems is a new industrial drying cabinet, specifically designed for optimized filament storage and conditioning. Together, these innovations forge a cohesive and powerful ecosystem, meticulously tailored to excel in high-mix, low-volume production scenarios. This article will delve into the intricate features and transformative capabilities of these two new industrial printers, along with the essential role of the new drying cabinet in achieving optimal additive manufacturing outcomes.

The Pro XL 3.1: Engineered for Precision, Designed for Unmatched Adaptability

The Pro XL 3.1 represents a significant leap forward in large-format industrial 3D printing, seamlessly blending expansive build capabilities with high-speed precision. This powerhouse machine boasts an impressive build volume of 600 × 400 × 600 mm, allowing for the creation of substantial parts or multiple components in a single print run. Crucially, it achieves this scale without compromising on speed, offering rapid print speeds of up to 500 mm/s. At its heart lies an upgraded CoreXY motion system, a sophisticated design known for its exceptional acceleration rates and remarkably quiet operation. This advanced system ensures precise and repeatable movements across the entire build plate, which is critical for intricate geometries and consistent part quality.

Thermal management is paramount for high-performance materials, and the Pro XL 3.1 addresses this with a meticulously designed heated bed capable of reaching temperatures up to 120 °C, alongside a heated chamber that maintains a stable environment up to 70 °C. These controlled thermal conditions are essential for printing engineering-grade filaments, preventing warping, and ensuring excellent layer adhesion, especially with demanding materials like ABS, PC, or high-performance composites.

Version 3.1 also introduces a fully modular Controller Area Network (CAN) bus architecture. This advanced communication protocol allows various devices within the printer to communicate efficiently and reliably, akin to the central nervous system of a modern vehicle. The CAN bus architecture provides unparalleled scalability, making it easy to integrate new modules or sensors in the future. Furthermore, it significantly simplifies servicing and diagnostics, as individual components can be isolated and addressed with greater ease, reducing potential downtime. The printer further enhances user convenience and print quality with its innovative QuickSwap printhead, featuring load-cell probing for automatic and highly accurate calibration. This intelligent probing system ensures perfect first layers and consistent print quality without manual intervention. Beyond its ease of use, the QuickSwap printhead is a high-speed marvel, capable of extruding an impressive 80 mm³/s, allowing for rapid material deposition and faster print completion.

Filament handling, often a bottleneck in industrial additive manufacturing, is meticulously optimized with dual DryCore modules. These modules provide active drying and pre-feeding functionalities, complete with automatic pellet regeneration, ensuring that filaments are kept in optimal condition throughout the printing process. This is crucial for hygroscopic materials that can absorb moisture, leading to print defects. Furthermore, a sophisticated recirculating air system, equipped with high-efficiency particulate air (HEPA) and activated carbon filtration, actively maintains stable climate conditions within the print chamber, safeguarding print quality and providing a cleaner working environment by capturing ultrafine particles and volatile organic compounds (VOCs). For operations requiring sustained, high-mix production without interruption, the Pro XL 3.1 offers optional upgrades such as an under-printer drying cabinet for additional filament storage and conditioning, and an auto spool changer supporting up to six 4.5 kg spools. These enhancements collectively position the Pro XL 3.1 as an exceptionally well-suited system for demanding industrial applications, offering unparalleled flexibility and continuous operation.

Pro XXL: Industrial Scale, Inherited Modular DNA

The Pro XXL takes FELIX 3D Printers’ renowned modular approach to an unprecedented scale within large-format industrial 3D printing. It offers a colossal build volume of 1500 × 1000 × 1000 mm, opening up new possibilities for manufacturing extremely large parts, batch production of components, or even architectural models and prototypes previously unachievable with conventional systems. Despite its monumental size, the Pro XXL astonishingly maintains the same impressive print speeds of up to 500 mm/s as its smaller counterpart, ensuring that industrial-scale production doesn’t equate to slower output. The secret to its incredible speed and precision lies in its sophisticated linear servo motor system, which features closed-loop feedback. This advanced motor system delivers an exceptional 2 µm resolution and accelerations of up to 2 G, guaranteeing high-speed performance without any compromise on the intricate precision required for industrial applications. Such accuracy is vital for large parts where cumulative errors can significantly impact the final product.

Stability and consistent layer adhesion across such a vast build area are ensured by the printer’s innovative Box-in-Box gantry design and a stationary print bed integrated with a four-zone vacuum system. The Box-in-Box gantry provides superior rigidity and minimizes vibrations, crucial for maintaining precision during high-speed movements across large distances. The four-zone vacuum system securely holds the print surface in place, preventing any movement or warping of the build plate, which is especially critical for producing large, complex components with demanding tolerances. This meticulous engineering ensures that even the largest prints benefit from consistent quality and reliability.

Mirroring the advanced capabilities of the Pro XL 3.1, the Pro XXL also incorporates the modular CAN-bus architecture, facilitating straightforward servicing, seamless integration of future upgrades, and enhanced system diagnostics. It also features the highly efficient QuickSwap printhead with load-cell probing for automatic calibration, ensuring optimal print quality and minimal setup time. Filament handling in the Pro XXL is similarly optimized for industrial scale, featuring active DryCore modules for consistent material conditioning, pre-feeding mechanisms, and an auto spool changer capable of managing up to four 4.5 kg spools. This automated system allows for continuous printing by automatically switching to a new spool when one runs out, dramatically reducing manual intervention and maximizing uptime. Furthermore, the Pro XXL includes the same robust air quality control features as the Pro XL 3.1, including HEPA and activated carbon filtration, underscoring FELIX’s commitment to both print quality and a safe operating environment, even on an industrial scale.

A Holistic Modular Ecosystem for the Smart Factory Floor

At Formnext 2025, FELIX 3D Printers is not merely showcasing individual machines but unveiling a complete, interconnected ecosystem designed to revolutionize factory floor operations. A central component of this ecosystem is its new industrial drying cabinet, a critical piece of equipment designed to ensure optimal filament conditions across an extensive range of materials. The cabinet’s intelligent modular design can accommodate up to four DryCore units, each capable of handling spools ranging from a compact 250 grams to heavy-duty 4.5 kilograms. With its precision-controlled environment, maintaining humidity levels below 10% and drying temperatures up to 90 °C, this cabinet ensures that even the most demanding, hygroscopic filaments are perfectly conditioned before and during printing. Proper filament drying is indispensable for preventing common print defects such as stringing, bubbling, and reduced mechanical properties, ultimately leading to higher print success rates and superior part quality.

All of FELIX’s advanced industrial systems are seamlessly supported by the company’s intuitive web-based print server. This powerful tool provides unparalleled remote team access, enabling engineers and operators to monitor ongoing print jobs via integrated webcams, control printer parameters, and manage queues from any browser, anywhere in the world. This level of remote control and monitoring is crucial for optimizing workflows, responding to issues promptly, and maximizing operational efficiency in a modern industrial setting. When combined with FELIX’s proprietary Cura-based FELIX Slicer Software, these integrated tools create a streamlined, efficient, and user-friendly workflow from initial setup and slicing to final production. This comprehensive software and hardware integration underscores FELIX’s commitment to delivering not just printers, but complete additive manufacturing solutions that empower businesses to harness the full potential of 3D printing.

With the introduction of the Pro XL 3.1, Pro XXL, and the new industrial drying cabinet, FELIX 3D Printers is unequivocally reinforcing its deep commitment to scalable, application-driven 3D printing solutions. These new systems, built on the company’s core philosophy of modularity and adaptability, position FELIX uniquely within the competitive industrial additive manufacturing landscape. They are designed not just to print parts, but to empower manufacturers with enhanced production power, efficiency, and flexibility, supporting their most ambitious production goals. To discover more about these transformative industrial systems and witness their capabilities firsthand, prospective customers and industry professionals are encouraged to visit FELIX 3D Printers at Formnext—Hall 12.1, booth F62. Further information can also be found by visiting their official website HERE.

What are your thoughts on the new FELIX Pro XL 3.1 and Pro XXL industrial 3D printers? Do you believe these modular systems will redefine industrial additive manufacturing workflows? Share your insights and opinions in the comments section below, or engage with us on our LinkedIn or Facebook pages. Additionally, don’t miss out on the latest advancements and news in the 3D printing industry by signing up for our free weekly Newsletter, delivered directly to your inbox. You can also explore a wealth of video content, interviews, and product demonstrations on our dedicated YouTube channel.

*All Photo Credits: FELIX 3D Printers