AIM3D showcases pellet printing updates at Formnext 2025: Voxelfill slicer and high-performance upgrade

AIM3D is using Formnext 2025 to showcase two technical highlights for 3D pellet printing: new slicer functions related to Voxelfill and a high-performance upgrade for the ExAM 255 and 510 series. The aim is to achieve greater component strength and higher efficiency in material extrusion. The partner is the Danish software provider Create it REAL, which provides Voxelfill as a “strong print” strategy in REALvision Pro.

Voxelfill addresses the well-known anisotropy of MEX components. Instead of printing exclusively layer by layer, the strategy fills defined volume areas in a staggered manner (“brick composite”). This significantly increases Z-strength. A paper in the RTe Journal reports a reduction in anisotropy from 56.71% to 13.47% for PETG with 30% glass fiber. This brings mechanical characteristics closer to injection molding references.

Create it REAL will deliver Voxelfill as a plug-in for REALvision Pro starting in November 2025. Access is modular and subscription-based, allowing users to combine functions according to their requirements. According to the provider, a low entry price is intended to promote adoption and accelerate further development through real-world applications. AIM3D is simultaneously developing SlicEx as its own solution for Voxelfill on ExAM systems; a beta is planned for the fourth quarter of 2025, with a market launch in 2026.

The high-performance upgrade targets process dynamics and dosing quality. “Input shaping” filters axis accelerations and dampens vibrations. This enables higher travel speeds and smoother edges. “Extruder pressure control” better linearizes screw feeding to the G-code. As a result, corners are less prone to material accumulation, interior areas show fewer cavities, and density increases. The upgrade is available for new and existing systems.

AIM3D also reports its first installations in the US, including at Fraunhofer USA Midwest and Cal Poly Pomona. This step addresses markets with high demands for high-performance polymers such as PEI (Ultem 9085) and PEEK. CTO Clemens Lieberwirth emphasizes that the combination of Voxelfill, slicer optimizations, and motion control noticeably improves surface quality and component quality. AIM3D also announces a high-temperature upgrade for the ExAM 255 with up to 120 °C build chamber heating for 2026.