Published 11/26/2024

7 Things We Saw at Formnext 2024 — Video Playlist

There were countless processes, applications and announcements at Formnext 2024. Here are seven standouts Peter Zelinski and Stephanie Hendrixson caught on film.

Stephanie Hendrixson

Executive Editor, Additive Manufacturing

Peter Zelinski

Editor-in-Chief, Additive Manufacturing

Skip ahead

Rocket Engine Printed in One Piece
Spherene Metamaterial
Binder Jetting — New Applications
Robotic AM Cell
Voxelfill — Ideal for Reinforced Polymers
Transparent 3D Printing
Modular, Automated Production to Compete with Injection Molding

As additive manufacturing’s largest trade show, Formnext in Frankfurt, Germany, offers an excellent window into new 3D printing technologies — as well as developments across the entire AM workflow. At the 2024 show, we discovered new materials and design strategies; AM’s integration with automation; and new applications for the manufacturing strategy. The videos below provide a sampling of what we saw on the show floor; scroll on or use the links in the sidebar to skip ahead.

More to come: Subscribe to the AM Radio podcast to hear our post-Formnext conversation with more trends, observations and takeaways from the show. Episode premieres December 3.

1. Rocket Engine Component 3D Printed in One Piece

This 3D printed rocket engine was produced in one step with no postprocessing required. Made with a laser powder fusion machine from Eplus3D, this 1,300-mm aluminum part took 354 hours to print and showcases generative design from Leap 71's AI-enabled computational tool. Watch here:

2. Spherene Metamaterial

This distinctive 3D printing geometry was developed by the Swiss startup Spherene. Unlike traditional lattices, spherenes are inverse sphere structures designed to distribute force evenly while reducing weight. This versatile geometry can be customized for applications like brackets, footwear and heat exchangers. Read our full article here and watch below:

3. New Applications for Binder Jetting

Binder jetting continues to advance, expanding the range of parts that can be cost-effectively 3D printed. In this video, Peter Zelinski highlights examples shown by Colibrium Additive. From knee implants to pump components and lightweight manifolds, see how binder jetting offers a lower-cost alternative to methods like electron beam melting and casting. Watch here:

4. Robotic Additive Manufacturing Cell

Robots and additive manufacturing combine in a single production cell to create a niobium aerospace nozzle. This demo created by VLM Robotics was running in Siemens’ booth during the show. Using a Siemens Sinumerik CNC controller, the cell integrates wire arc additive manufacturing (WAAM), machining, niobium spraying and metrology — all without moving the part between processes. Watch here:

5. Voxelfill — Ideal for Reinforced Polymers

AIM3D's Voxelfill technique blends 3D printing with injection molding to overcome the strength limitations of fused filament fabrication (FFF). Showcased at Formnext 2024, this patented method uses injected material to reinforce the Z axis of 3D printed parts, filling a hexagonal structure to improve durability. Particularly effective with reinforced polymers, Voxelfill randomizes fiber alignment for balanced strength. Watch here:

6. Transparent 3D Printing with New PETG Material

Airtech introduced a transparent PETG material for 3D printing at Formnext 2024. Designed as a granulate material, it requires no special processing to achieve transparency. This material transitions Airtech’s focus from tooling to end-use parts, opening up possibilities for applications like lighting, transparent furniture and custom-shaped 3D windows. This video shows the material’s as-printed finish, along with a polished example, and explains its potential for innovative designs. Watch here:

7. Modular Systems for Automated 3D Printing Production

Automation in 3D printing often involves external cobots tending machines, but Photocentric’s JENI production system integrates most of the automation directly into its modular platform. Designed for high-volume serial production, the system features 12 customizable stations per module for printing, washing, curing and rinsing, all managed by an internal gantry system. Modules can be arranged side-by-side and scaled up for redundancy, allowing for seamless repairs without production interruptions. Watch here: