Post-processing technologies in the spotlight at Formnext

The recent Formnext 2025 exhibition held in Novmeber confirmed the accelerating pace of the development of additive manufacturing (AM), with record visitor numbers and a broad range of applications highlighting its steady transition into an industrial standard. One of these — post-processing — is critical to making 3-D printing viable for true series production.

David Soldan, head of AM Solutions — 3D post-processing technology, said: “Despite ongoing market consolidation, we are seeing strong demand for solutions that enable cost-efficient and reproducible post-processing to move AM forward. Automated processes not only help secure consistent quality standards but also actively counteract the skilled-labour shortage.”

AM Solutions presented a portfolio at Formnext designed to meet the specific requirements of AM, combining proven systems with new developments. Established models such as the S1 and S2 continue to deliver the two-in-one process for cleaning and surface finishing, while new systems including the M4 Basic and M1 offer scalable solutions for surface finishing, from compact entry-level units to mid-range and high-volume capacities. Automation was a major focus, with the F1 and D1 systems—co-developed with EOS — demonstrating readiness for industrial deployment following extensive beta testing.

The F1 system automates sieving and mixing of new and recycled powder with dosing accuracy of ±2%, handling up to 45kg per hour and increasing throughput by more than 30%. Its process reduces the proportion of new powder required and shortens dwell time, lowering part costs. The D1 system, tested at a Swiss medical technology company, halved unpacking time for dense build jobs and reduced labour requirements by up to 80%.

Vapour-smoothing capability
It also enabled unpacking before full cooling, eliminating waiting times of up to 10hr. Both systems improve profitability and reproducibility through closed-loop architecture, marking a significant step toward fully automated, series-ready SLS production. Another highlight was AM Solutions’ strategic partnership with LuxYours, adding vapour-smoothing capability to its portfolio. LuxYours’ patented ‘Multi Purpose Smoothing’ technology refines thermoplastic parts from processes such as SLS, MJF, HSS, SAF, AKF and FDM, preserving fine details while smoothing internal channels. This physico-chemical process offers a controlled approach that enhances surface quality without compromising geometry.

A case study from Formrise demonstrated the impact of AM Solutions’ S1 system, which combines cleaning and finishing in a single step using one medium. Since 2024, Formrise has operated three S1 systems, achieving a 60% reduction in Polybead consumption, an 87% reduction in glass bead usage, CO₂ savings of 1.6 tonnes, and a 50% cut in processing time. Electricity and compressed air consumption fell significantly, disposal costs were reduced, and part quality remained consistently high. Annual savings approached 35,000 euros, with more than half attributable to reduced air consumption.

These developments underline the growing importance of automated post-processing in additive manufacturing. By improving efficiency, reducing resource use, and ensuring repeatable quality, solutions such as those presented at Formnext are helping AM transition from prototyping to true industrial-scale production.