Automated post-processing moves into the spotlight at Formnext 2025

At the trade fair, the company presented a clearly structured portfolio for polymer and metal applications. The S1 and S2 systems combine cleaning and surface finishing in a 2-in-1 process, while M4, M4 Basic and M1 are designed for different throughput requirements in mass finishing and blasting. New to the lineup are the F1 and D1 automation modules for SLS workflows developed jointly with EOS, which have been tested in beta installations at industrial customers. In practice, D1 halved the unpacking time of a fully built job for a medical technology user, while F1 at FORMRISE stabilized powder preparation with a dosing accuracy of ±2 percent, mixed up to 45 kilograms per hour and significantly reduced manual effort.

A case study with three S1 systems at FORMRISE quantifies the effects: up to 60 percent fewer polybeads, 87 percent fewer glass beads, around 1.6 tons of CO₂ savings per year, and processing times cut in half. The reduced compressed air consumption alone contributes to annual cost savings of just under 35,000 euros.

Strategically, AM Solutions is expanding its portfolio through an investment in LuxYours. Its Multi Purpose Smoothing process enables physico-chemical smoothing of complex thermoplastic components from SLS, MJF, HSS, SAF, AKF and FDM, including internal channels. In parallel, the AutoSmooth research project addresses the post-processing of Cold-Metal-Fusion parts; more recent results point to fully recyclable feedstock and closed material cycles.

Formnext 2025 thus makes it clear that automated post-processing is becoming a key lever for transforming 3D printing processes into scalable, series-ready production chains.