EOS unveiled the EOS M4 Onyx metal system at Formnext 2025, a new platform for laser powder bed fusion on an industrial scale. The system is tailored to users in the energy, aerospace, defense and semiconductor industries who require larger components and higher utilization in existing AM environments.
The machine offers a build volume of 450 × 450 × 400 millimeters and, in its standard configuration, operates with six 400-watt lasers. EOS cites up to 50 percent higher throughput and significantly reduced part costs compared to existing systems in its own product range. An FLX variant with four 1-kilowatt lasers is intended to deliver additional exposure speed and flexibility in process control for suitable geometries. Homogeneous gas flow, active temperature control and integrated error detection are aimed at stable loading conditions and reduced inspection effort.
“At EOS, our customers have always been at the heart of every innovation. The launch of the EOS M4 ONYX is a testament to our legacy as pioneers in additive manufacturing and our commitment to empowering manufacturers worldwide,” said Marie Langer, CEO, EOS. “This optimized system was only made possible by the dedication and expertise of our global team, whose relentless pursuit of AM excellence continues to set new standards for the industry. Together, we are shaping the future of metal 3D printing productivity and responsible manufacturing, delivering the highest quality solutions for our customers.”
On the software side, EOS relies on Build+ in combination with a Siemens control system. Open interfaces and web APIs are intended to simplify integration with MES and ERP systems and shorten order-to-print time. Features such as early status notifications and digital fingerprints with statistical process control are designed to reduce non-destructive testing without sacrificing documented quality assurance. Smart Fusion and Smart Fusion Replay control energy input layer by layer and are intended to limit support structures and post-processing.
For operating the M4 Onyx, EOS positions coordinated peripheral equipment. The RFS Pro filter system enables extensive powder recovery and neutralizes condensed residues to simplify maintenance and disposal. Volkmann supplies automated powder management in a closed loop, while a Grenzebach dual setup station is intended to support build job changeovers in under 30 minutes and automated night-time job starts.
“At EOS, we live by our longstanding commitment to efficiency, safety, and innovation. Those pillars along with AM manufacturing innovations from partners like Volkmann and Grenzebach, have culminated in our most productive metal AM system to date,” said Sebastian Becker, Head of Product Management Metal at EOS. “Beyond the technical milestone of our RFS Pro, our customers will benefit from our deep collaborative relationships to successfully scale their AM production with confidence and consistency.”
The EOS M4 Onyx is scheduled to be available in the first quarter of 2026, with the FLX variant to follow in the third quarter, according to the company. Initial support will cover titanium, nickel and stainless steels, with additional alloys planned. For operations looking to move metal 3D printing from the prototyping phase into near-series production with traceable process data, EOS is offering a new option in the upper performance range of LPBF systems.
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