KraussMaffei will showcase its powerPrint Flex, a modular 3D printing solution for large-format components and tools, at Formnext in Frankfurt on November 18-21, 2025. Following the success of the closed 3D printing system powerPrint Plus, KraussMaffei is now offering maximum flexibility with robot-based manufacturing cells.

KraussMaffei’s powerPrint Flex.

Responding the growing applications of industrial 3D printing, KraussMaffei’s powerPrint Flex combines the proven extrusion technology with a modular architecture, offering manufacturers a high degree of freedom in terms of design and materials. The production cells can also be scaled and individually configured to meet specific customer needs.

Live demo: Thin-walled car component

At its booth, the powerPrint Flex will produce a carbon fibre-reinforced polycarbonate rear diffuser for a sports car.

Large-format 3D printing enables the rapid, tool-free production of large, thin-walled components with high rigidity and precision, making it 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 developed extruder: printCore 35-25

The standard configuration of powerPrint Flex includes a Comau N-170 robot within the cell, with various customization options available.

The print bed measures 2500 x 2000 mm, can be heated up to 180 °C, and features 16 vacuum zones for the printing plates.

KraussMaffei’s in-house developed extruder, printCore 35-25, enables high output rates from 30 to 70 kg per hour, depending on the material feed system.

KraussMaffei’s in-house developed extruder – printCore.

With a maximum melting temperature of 400°C, even the most demanding fibre-reinforced thermoplastics and high-performance polymers can be processed. This makes the system suitable for use in the automotive and aerospace industries, as well as for tool manufacturing and general industrial projects.

Flexible integration of robot

powerPrint Flex uses the Sinumerik One system from Siemens to control its six-axis robot. This control system enables precise, dynamic and consistently networked motion control.

Thanks to its modular design, powerPrint Flex can be integrated into existing manufacturing environments and expanded with additional functions, such as rotary tables or milling centers. This results in a fully developed solution that are optimally tailored to the respective production process.