Greater system flexibility in industrial 3D printing with KraussMaffei

At Formnext (Frankfurt/Main, November 18-21, 2025), KraussMaffei will present powerPrint Flex, a modular 3D printing solution for large-format components and tools. Following the success of the closed 3D printing system powerPrint Plus, KraussMaffei now offers maximum flexibility through robot-assisted manufacturing cells. The modular powerPrint Flex concept will be on display at Formnext (Hall 12.1 / Booth E119).

Projects are becoming increasingly diverse. From designer seating and thin-walled automotive components to tools for resin transfer molding (RTM), industrial 3D printing is conquering areas with a wide variety of requirements. powerPrint Flex, the compact and powerful robot solution from KraussMaffei, offers maximum flexibility for this purpose. The system combines KraussMaffei’s proven extrusion technology with a modular architecture, giving manufacturers a high degree of freedom in terms of designs and materials. With powerPrint Flex, production cells can be scaled and individually adapted to customer requirements.

A thin-walled component is created

At the Formnext trade fair, KraussMaffei will demonstrate how powerPrint Flex is used to create a rear diffuser for a sports car made of carbon fiber-reinforced polycarbonate. Large-format 3D printing enables the fast and tool-free production of large-area, thin-walled components with high rigidity and precision – ideal for functional prototypes and design studies. This allows design changes to be implemented immediately, development times to be shortened, and costs to be significantly reduced.

In-house development: printCore 35-25 extruder

In addition to the cell, the standard equipment of the powerPrint Flex includes a Comau N-170 robot, whereby a wide range of customizations are possible. The print bed measures 2500 x 2000 mm, can be heated to 180 °C, and has 16 vacuum zones for the printing plates. The printCore 35-25 extruder, developed in-house by KraussMaffei, enables high output rates of 30 to 70 kilograms per hour, depending on the material supply used. The maximum melt temperature of 400 °C also allows demanding fiber-reinforced thermoplastics and high-performance polymers to be processed, making the system suitable for applications in the automotive and aerospace industries as well as for tool manufacturing and general industrial projects.

Flexible integration of the robot into modular manufacturing systems

powerPrint Flex uses the Sinumerik One system from Siemens to control the six-axis robot. This control system enables consistently networked, precise, and dynamic motion control. Thanks to its modular system design, powerPrint Flex can be specifically integrated into existing production environments and expanded with additional functions – for example, with rotary tables or milling centers. This results in fully developed solutions that are optimally tailored to the respective production process.

Hardware, consulting, service

KraussMaffei’s decades of expertise in various areas of plastics processing form the basis for the company’s strategy in the field of additive manufacturing. The systems enable industrialized 3D printing with high precision, consistent quality, and scalable efficiency. Customers benefit from comprehensive technical expertise – supported by solution-oriented consulting and a global service network. KraussMaffei also helps manufacturers create their business case and offers support in the development of customized additive manufacturing or hybrid production systems.