KraussMaffei will present the modular 3D-printing solution powerPrint Flex for large-format components and tools at Formnext (Frankfurt am Main, November 18–21, 2025). Following the success of the enclosed 3D-printing system powerPrint Plus, KraussMaffei now offers maximum flexibility through robot-supported manufacturing cells. The modular concept powerPrint Flex can be seen at Formnext (Hall 12.1 / Booth E119).
Projects are becoming increasingly diverse. From designer seating furniture and thin-walled automotive components to tools for resin transfer molding (RTM): industrial 3D printing is entering fields with a wide variety of requirements. powerPrint Flex, the compact and powerful robot solution from KraussMaffei, offers maximum flexibility to meet these demands. The system combines KraussMaffei’s proven extrusion technology with a modular architecture, giving manufacturers extensive freedom in design and material selection. With powerPrint Flex, production cells can be scaled and individually adapted to customer needs.
A Thin-Walled Component Takes Shape
At Formnext, KraussMaffei will demonstrate how a rear diffuser for a sports car can be produced from carbon-fiber-reinforced polycarbonate using powerPrint Flex. Large-format 3D printing enables the fast, tool-free production of large-area, thin-walled components with high stiffness and precision – ideal for functional prototypes and design studies. Design changes can thus be implemented immediately, development times shortened, and costs significantly reduced.
In-House Developed Extruder printCore 35-25
The standard configuration of powerPrint Flex includes the cell with a Comau N-170 robot, while offering a wide range of customization options. The print bed measures 2,500 x 2,000 mm, can be heated to 180°C, and features 16 vacuum zones for build plates. The proprietary KraussMaffei extruder printCore 35-25 enables high output rates of 30 to 70 kilograms per hour, depending on the material feed system used. With a maximum melt temperature of 400°C, even demanding fiber-reinforced thermoplastics and high-performance polymers can be processed, making the system suitable for applications in the automotive and aerospace industries as well as for toolmaking and general industrial projects.
Flexible Integration of the Robot into Modular Manufacturing Systems
The powerPrint Flex uses Siemens’ Sinumerik One system to control the six-axis robot. This control system enables fully networked, precise, and dynamic motion control. Thanks to the modular system design, powerPrint Flex can be specifically integrated into existing manufacturing environments and expanded with additional functions – for example with rotary tables or milling centers. This results in fully engineered solutions optimally tailored to the respective production processes.
Hardware, Consulting, and Service
KraussMaffei’s decades of expertise across various areas of plastics processing form the basis of the company’s strategy in additive manufacturing. Its systems enable industrialized 3D printing with high precision, consistent quality, and scalable efficiency. Customers benefit from comprehensive technical competence, supported by solution-oriented consulting and a global service network. KraussMaffei also assists manufacturers in developing their business cases and offers support in designing customized additive manufacturing or hybrid production systems.
