KraussMaffei unveils powerPrint Flex: modular robotic cell for large-format 3D printing

KraussMaffei is presenting powerPrint Flex at Formnext 2025 (Frankfurt/Main, November 18–21; Hall 12.1, Booth E119), a configurable 3D printing solution for large-format parts and tools. Following the closed powerPrint Plus system, the new concept targets applications that require variable work envelopes, material options, and downstream processing. The goal is tool-free production of large-area components in manageable iteration cycles—from designer furniture and thin-walled automotive parts to RTM tools.

Technically, powerPrint Flex combines a six-axis industrial robot with a high-throughput extruder and a heated build platform. In the standard configuration, a Comau N-170 is used; the build plate measures 2.500 × 2.000 mm, can be heated up to 180 °C, and is segmented into 16 vacuum zones. The in-house printCore 35-25 extruder achieves 30 to 70 kg/h depending on material supply and processes melts up to 400 °C. This enables the processing of fiber-reinforced thermoplastics and high-performance polymers, such as carbon-fiber-reinforced polycarbonate for stiff, thin-walled structures.

At the show, KraussMaffei is demonstrating the production of a rear diffuser for a sports vehicle. Large-format extrusion printing enables direct implementation of design changes without mold and toolmaking. For prototypes and pre-series, short turnaround times and reproducible wall thicknesses are crucial; the combination of heated table, high discharge rate, and robotics aims for stable process control with varying geometries.

The cell uses Siemens Sinumerik One for path planning and end-to-end connectivity. Thanks to the modular design, turntables, milling units, or additional axes can be integrated to combine hybrid processes such as printing and trimming in a single system. KraussMaffei points to accompanying services ranging from business-case evaluation and material/process selection to commissioning. For users in automotive, aerospace, and toolmaking, this provides a scalable option to integrate large-format thermoplastic parts into existing production environments and make validation efforts more predictable.