At Formnext 2025, AIM3D is showcasing where 3D pellet printing is headed: alongside new slicer tools from its collaboration with Create it REAL, the Rostock-based company is announcing a high-performance upgrade for the ExAM 255 and ExAM 510 systems. At the center is Voxelfill, a volumetric infill strategy that addresses the anisotropic strengths of classic MEX parts and targets tensile properties approaching those of injection-molded, fiber-reinforced plastics.
On the software side, there are two tracks: Create it REAL is integrating Voxelfill as a “Strong-Print” option in REALvision Pro, thereby opening the strategy to filament systems as well. According to the provider, modular plug-ins are available on a monthly subscription, with the base package starting at €4.38. In parallel, AIM3D is developing SlicEx, its own implementation for ExAM machines, slated for market launch in 2026. Scientific backing comes from a study published in the RTe Journal, which reduced the degree of anisotropy in PETG with 30 percent glass fiber from 56.71 to 13.47 percent—achieved through volumetric filling instead of purely layer-wise paths.
Clemens Lieberwirth, CTO at AIM3D: “The High Performance Upgrade comprises two optimization modules: Firstly, ‘Input Shaping’, which acts as a filter for the acceleration of the axes, increasing component quality at high travel speeds, and secondly, ‘Extruder Pressure Control’ for improved dosing and higher component quality.”
The high-performance upgrade intervenes directly in the machine control. “Input shaping” filters the acceleration profiles of the axes, reduces vibrations, and improves edge quality at higher travel speeds. “Extruder pressure control” linearizes dosing of the screw extruder across speed changes, reduces material build-up in corners, and closes voids—particularly relevant for high-performance polymers and fillers when dense, fluid-carrying components are required.
Dr. Vincent Morrison, CEO of AIM3D: “Of course, the size and innovative strength of the US industry in the automotive, aerospace, defense, and energy sectors promises high growth potential for the 3D pellet printing strategy.”
Dr. Bastian Gaedike, CEO of Malping: “On the one hand, the price advantage in terms of material costs, especially for high-priced high-performance plastics, is obvious and a clear competitive advantage for 3D pellet printing. On the other hand, the continuous developments in 3D pellet printing by AIM3D with the Voxelfill strategy, optimized slicers, and system upgrades offer significant levers for process stability, component quality, and build rates. I see enormous value creation potential in 3D pellet printing in the future.”
AIM3D is also making commercial moves: in 2025 two ExAM 255 systems went to Fraunhofer USA Midwest and Cal Poly Pomona, with an ExAM 510 to follow at an automaker in Detroit. CEO Vincent Morrison sees this as a signal for the U.S. market, which is “increasingly recognizing the material-cost advantages of pellet printing.” The trade-show presence is accompanied by service provider Malping, which contributes process and materials expertise for PEEK and PEEK-CF applications.
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