Automated post-processing: AM Solutions shows at Formnext where 3D printing is stuck

At Formnext 2025, AM Solutions demonstrated how strongly the profitability of additive manufacturing depends on the automation of post-processing. The focus was on systems for automated unpacking, powder preparation, and surface finishing of plastic and metal parts from SLS and related powder bed processes.

“Despite consolidation in the market, we are seeing strong interest in solutions for economical and reproducible post-processing to advance 3D printing. Automated processes not only help to secure quality standards, but also actively counteract the shortage of skilled workers,” emphasizes David Soldan, Head of AM Solutions – 3D post processing technology.

The systems F1 and D1, developed jointly with EOS, have been transferred into regular operation at industrial customers after a beta program. The F1 mixes virgin and used powder with a dosing accuracy of around ±2 percent and enables throughputs of up to 45 kilograms of powder per hour, which, according to the manufacturer, has led to a significant increase in build job capacity at FORMRISE.

The D1 takes over the complete unpacking of build jobs with high part density. In a case study at a Swiss medical technology company, unpacking time was cut in half, while direct operator effort fell by up to 80 percent, since employees primarily carry out loading and unloading operations. In addition, parts can already be processed before they have fully cooled down, eliminating long waiting times.

In parallel, AM Solutions presented a tiered portfolio for blasting and finishing plastic parts with the S1, S2, M1, and M4. A case study with three S1 systems at FORMRISE shows significantly reduced blasting media consumption, lower disposal costs, and consistent surface quality.

Another focus was the AutoSmooth research project centered on ColdMetalFusion components. Initial results indicate that the feedstock used is fully recyclable. For industrial users in 3D metal printing, a closed material loop would be a relevant factor in measurably reducing unit costs and the CO₂ footprint of the process chain.