Formnext 2025: HP advances industrial additive manufacturing with new materials and filament systems

At Formnext 2025 in Frankfurt, HP Additive Manufacturing is clearly positioning its Multi-Jet Fusion and Metal Jet platforms as tools for series production. The focus is on lower unit costs, new polymer and metal materials, and an expanded hardware portfolio for industrial 3D printing.

HP points to around a decade of experience with MJF systems and aims to reduce costs per component by up to 20 percent by 2026. To achieve this, the manufacturer is combining optimized printing processes with new materials. One example is HP 3D HR PA 11 Gen2, which allows powder reuse of up to 80 percent and reduces variable part costs by up to 40 percent, according to HP. At the same time, the material is said to have a lower carbon footprint than previous MJF plastics.

In the metal sector, HP is strengthening the Metal Jet ecosystem. Continuum Powders and INDO-MIM have qualified OptiPowder Ni718 for the HP Metal Jet S100. The nickel-based material enables highly compacted, sintered components and is aimed at applications in aerospace, energy, and defense. At the same time, HP is working with Continuum and Tecnalia to develop OptiPowder M247LC, a low-carbon superalloy for high-temperature components, as well as other specialty nickel alloys for binder jet processes.

Together with GKN Powder Metallurgy, HP plans to expand access to copper applications. The plan is to develop precision components for cloud infrastructure, electromobility, and thermal management that will enable efficiency gains in data centers and power electronics.

Another new development is the company’s entry into industrial filament solutions. With HP Industrial Filament 3D Printing Solutions, the company is targeting users who employ high-temperature and engineering polymers in FFF processes. The platform is based on an open material strategy and is supported by HP’s existing service network.

The first system is the HP Industrial Filament 3D Printer 600 High Temperature (IF 600HT) for high-temperature filaments, which is scheduled for release in the first half of 2026. The HP Industrial Filament 3D Printer IF 1000 XL with a large build volume and modular architecture is announced for the second half of 2026 and targets voluminous components.

At the same time, HP is expanding its digital production chain. The Additive Manufacturing Network and a partnership with the Würth Additive Group are creating workflows for digital inventories and on-demand manufacturing. The integration of the 3MF Secure Content Extension is designed to deliver protected print data and traceable processes directly to HP systems.