Formnext 2025: Key Trends and Innovations in Additive Manufacturing

Formnext, the leading trade fair for additive manufacturing (AM), consistently provides a valuable overview of the industry’s direction. This year’s event featured a compelling blend of hardware, software, and workflow enhancements. While not every announcement generated widespread buzz, several developments clearly indicated the industry’s focus on automation, accessibility, and multi-material capabilities. This article highlights some of the most noteworthy releases that captured our attention at the show.

Materialise CO-AM Platform Expansion: Streamlining AM Workflows

Materialise made a significant software announcement with the expansion of its CO-AM platform. The platform now offers three new configurations: Professional, NPI (New Product Introduction), and Enterprise. These configurations are powered by CO-AM Brix, a low-code automation layer designed to simplify the creation, customization, and scaling of workflows across multiple sites. This innovation, combined with the new cloud-based CO-AM Build Platform and a modular next-generation Build Processor framework, represents a substantial step toward more open and flexible end-to-end AM management. Materialise’s commitment to streamlining the AM process is evident in this comprehensive platform update.

The CO-AM platform’s expanded capabilities address a crucial need in the additive manufacturing industry: the need for seamless integration and automation. By providing a low-code automation layer, Materialise empowers manufacturers to create custom workflows tailored to their specific needs. This flexibility is essential for businesses looking to scale their AM operations and optimize their production processes. The cloud-based CO-AM Build Platform further enhances accessibility and collaboration, allowing teams to work together more effectively regardless of their location. The modular Build Processor framework offers future-proof scalability and adaptability, ensuring that the platform can evolve to meet the changing demands of the industry.

This software advancement directly tackles the challenges of managing complex additive manufacturing processes. It aims to bridge the gap between design and production, enabling smoother transitions and reduced errors. The emphasis on customization through the low-code environment allows companies to adapt the platform to their specific workflows, rather than forcing them to adapt their workflows to the platform. This user-centric approach could significantly improve efficiency and reduce the learning curve associated with implementing new AM technologies.

XJet Carmel PRO: NanoParticle Jetting for Wider Audiences

Our team also visited XJet, where the new Carmel PRO was showcased. This system brings XJet’s innovative NanoParticle Jetting (NPJ) technology to a broader audience. The Carmel PRO is designed to be more accessible than previous XJet systems, making it an attractive option for companies looking to explore the benefits of NPJ technology without a significant upfront investment. Furthermore, the machine can now handle up to four materials in a single job, opening up new possibilities for multi-material parts and complex designs. The introduction of the Carmel PRO marks a significant return for XJet, particularly in sectors that demand fine detail, such as medical devices, jewelry, and precision industrial components.

NPJ technology offers distinct advantages, including the ability to produce parts with exceptional accuracy, smooth surfaces, and intricate geometries. The Carmel PRO’s increased accessibility and multi-material capabilities further enhance its appeal. The ability to combine different materials in a single print allows for the creation of functional prototypes and end-use parts with tailored properties. This is particularly valuable in applications where specific material combinations are required to achieve desired performance characteristics. The improved accessibility of the Carmel PRO also means that smaller businesses and research institutions can now benefit from the advantages of NPJ technology.

The Carmel PRO’s focus on accessibility and multi-material printing directly addresses two key challenges in the additive manufacturing industry: the high cost of entry and the limited availability of multi-material solutions. By making NPJ technology more affordable and versatile, XJet is contributing to the democratization of additive manufacturing and empowering a wider range of businesses to innovate and create new products. The potential applications for the Carmel PRO are vast, ranging from customized medical implants to intricate jewelry designs and high-performance industrial components.

Bambu Lab H2C: Automation and Multi-Material Printing on the Desktop

Bambu Lab generated considerable interest with the debut of the H2C. This system introduces the Vortek Hotend Change mechanism, which supports up to six smart hotends and 24 filaments. However, what truly stood out was the emphasis on automation. The H2C features quick tool changes, minimal purging, built-in cameras, and a streamlined multi-material workflow, all designed to simplify the production of complex parts within a desktop-friendly ecosystem. Bambu Lab’s H2C represents a significant step forward in making multi-material printing more accessible and user-friendly.

The H2C’s automation features address a common pain point in multi-material printing: the complexity of managing multiple filaments and ensuring efficient tool changes. By automating these processes, Bambu Lab has significantly reduced the amount of manual intervention required, making multi-material printing more accessible to a wider range of users. The built-in cameras provide real-time monitoring of the printing process, allowing users to identify and address any issues that may arise. The streamlined multi-material workflow further simplifies the process, making it easier to create complex parts with multiple materials.

The H2C’s emphasis on automation and user-friendliness reflects a growing trend in the additive manufacturing industry: the desire to make AM technology more accessible to non-experts. By simplifying the printing process and reducing the learning curve, companies like Bambu Lab are empowering individuals and small businesses to explore the potential of additive manufacturing without requiring specialized training or expertise. The H2C’s desktop-friendly ecosystem further enhances its appeal, making it an ideal solution for prototyping, education, and small-scale production.

HP and EOS: Expanding Capabilities in FDM and Metal AM

HP made its debut in the high-performance FDM (Fused Deposition Modeling) segment with a new machine that brings familiar MJF (Multi Jet Fusion)-style usability to filament extrusion. This system also incorporates strong thermal control and automation features, contributing to a more efficient and reliable printing process. In the realm of metal AM, EOS presented the M4 ONYX, a six-laser system designed to increase throughput and improve powder handling efficiency. This incremental but relevant step contributes to the scalability of series production in metal additive manufacturing.

HP’s entry into the high-performance FDM market expands the range of options available to manufacturers seeking to produce large, functional parts with FDM technology. The machine’s MJF-style usability simplifies the printing process and reduces the learning curve, while the thermal control and automation features ensure consistent and reliable results. EOS’s M4 ONYX addresses the need for increased throughput and efficiency in metal additive manufacturing. The six-laser system allows for faster printing speeds, while the improved powder handling system minimizes waste and reduces the risk of contamination. These advancements contribute to the overall cost-effectiveness and scalability of metal AM.

These developments from HP and EOS reflect the ongoing efforts to improve the performance, reliability, and cost-effectiveness of both polymer and metal additive manufacturing technologies. By expanding the range of available solutions and addressing key challenges in the AM process, these companies are contributing to the wider adoption of additive manufacturing in a variety of industries.

Formnext 2025: A Maturing Industry

Formnext 2025 may not have featured a single, groundbreaking innovation, but the launches highlighted demonstrate the additive manufacturing industry’s continued maturation. The emphasis on smarter automation, broader accessibility, and more specialized tools for both polymer and metal production indicates a clear direction for the future of AM. The industry is moving towards more integrated, user-friendly, and cost-effective solutions that can be readily adopted by a wider range of businesses.

The trends observed at Formnext 2025 suggest that the additive manufacturing industry is entering a new phase of maturity. The focus is shifting from simply developing new technologies to refining existing ones and making them more accessible and practical for real-world applications. This is a positive sign for the industry, as it indicates a growing understanding of the needs of manufacturers and a commitment to providing solutions that address those needs effectively.

What do you think of these updates? How will they impact the future of additive manufacturing?