Farsoon Europe and automotive supplier Brose are jointly working on a metal 3D printer specifically designed to meet the requirements of high-volume automotive production. A special feature of the system is its ability to process a sustainable metal powder produced entirely from recycled steel scrap from Brose’s press plants. This makes it possible to address CO₂ targets without sacrificing part quality or productivity.
The technical basis is the FS721M-8-CAMS with a build volume of 720 × 420 × 390 millimeters, optionally expandable to 650 millimeters in build height. Farsoon has equipped the system for Brose with eight lasers, each providing up to 2,000 watts of power, which is significantly higher than what is common in laser powder bed fusion. The high number of lasers is aimed at short build times and economically viable series production of complex geometries.
A central role is played by Farsoon’s patented beam-shaping technology. Instead of conventional point spots, ring-shaped, larger spot diameters are used, which are intended to ensure a homogeneous melt pool and thereby stabilize part quality. This is complemented by the CAMS concept (Continuous Additive Manufacturing System): finished build jobs are removed as containers, while a new build cylinder is inserted immediately. This significantly reduces laser idle time during setup and cooling phases.
“The advanced system supplied by Farsoon enables us to profitably produce larger series thanks to higher throughput and shorter production times. With the FS721-8-CAMS, Brose can now produce more components per production order, shorten cycle times and increase overall profitability – making additive manufacturing an economical solution for high-volume applications,” explains Eric Fritzsche, Head of Additive Manufacturing. “An outstanding feature of the innovative 3D printer is its compatibility with ‘Green Steel’, a low-alloy steel material that supports our commitment to sustainable production.”
In addition to the hardware, the software has also been optimized for high packing densities and the handling of large part counts per job. One example is a build job with more than 21,000 components manufactured without support structures, which is suitable for fully automated post-processing.
“Together with Brose, we turned innovation into real production efficiency — a great example of what strong partnership and open technology can achieve,” said Oliver Li, Managing Director of Farsoon Europe. “The combination of material, component design and perfectly matched printers thus represents a very valuable milestone for the future.”
Farsoon also regards the project as an important step toward industrial series applications. Managing Director Oliver Li emphasizes the combination of suitable material, adapted part design and matching machine technology as a key building block for future AM projects in the automotive sector. At Formnext 2025 in Frankfurt (Hall 11.0, Booth E11), the two partners plan to demonstrate how metal 3D printing with recycled materials can be integrated into existing manufacturing strategies.
Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
