Aim 3D's Latest Advances in 3D Pellet Printing Unveiled at Formnext 2025

Aim 3D at Formnext Aim 3D and Create it Real boost strength and efficiency in pellet printing

2025-11-07 Source: Aim 3D 3 min Reading Time

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The 2025 Formnext appearance of Aim 3D will highlight new developments in 3D pellet printing, featuring the High Performance Upgrade for the ExAM 255 and ExAM 510 systems and Voxelfill-based slicer tools developed with Create it Real to improve strength, precision and efficiency.

3D pellet printing in the USA: an Exam 255 at the Fraunhofer USA Center Midwest in East Lansing, Michigan.(Source: Aim 3D) — 3D pellet printing in the USA: an Exam 255 at the Fraunhofer USA Center Midwest in East Lansing, Michigan.
(Source: Aim 3D)

At the Formnext 2025, Aim 3D will present its latest developments in 3D pellet printing. The main development activities in 2025 resulted in new slicer tools in collaboration with development partner Create it Real and, as a premiere, a high-performance upgrade for the Exam 255 and Exam 510 systems. Both offer advances in 3D pellet printing in terms of quality and efficiency. The trade fair appearance will be accompanied by Malping, a 3D printing service provider for application and material expertise, design and 3D processes. Last but not least, Aim 3D will provide insights into projects with new customers in the United States.

Aim 3D's patented Voxelfill process overcomes inhomogeneous strengths of 3D components in the X, Y and Z axes. Aim 3D is currently developing its own Slicex slicing software for the implementation of Voxelfill on the Exam 255 and Exam 510 systems, which is scheduled for market launch in 2026. Users will be able to get a taste of the potential of the Voxelfill process as early as November 2025: Software development partner Create it Real offers a plug-in for higher tensile strengths for 3D construction jobs with Voxelfill. Create it Real’s slicer tools are also available for industrial users of filament extrusion technology. To ensure rapid market penetration, Create it Real has also announced attractive pricing models for the consumer segment.

Gallery

Fiber distribution with Voxelfill(Source: Aim 3D)

Higher component quality: Comparison image of a component with and without Aim 3D’s High Performance Upgrade(Source: Aim 3D)

Standard slicer: Realvision-Pro Slicer from Create it Real for 3D filament printers(Source: Aim 3D)

Gallery with 8 images

Aim 3D and software development partner Create it Real have made a strategic decision to offer the benefits of the Voxelfill strategy for exploiting higher tensile strengths not only to the users of Aim 3D systems (Exam 510 and Exam 255), but also to industrial users of 3D filament systems (FFF printers). The Realvision-Pro Slicer with Voxelfill — named Strong-Print strategy — from Create it Real thus opens up a wide range of possible industrial applications. Furthermore, the pricing model for the Realvision-Pro Slicer is not only aimed explicitly at industrial customers but is also affordable for consumer users.

Aim 3D introduces High Performance Upgrade 2025

For Aim 3D, the focus in 2025 is on enhancing the efficiency of the 3D extrusion printing process. The company’s Exam 255 and Exam 510 pellet printers now deliver component quality and process stability that allow the use of established materials with minimal or no post-processing requirements. With the Voxelfill strategy, tensile strength values are now being achieved that are comparable to the parameters of classic injection molding with fiber-reinforced materials. In order to further optimize the cost-effectiveness of 3D pellet printing, Aim 3D has developed a High Performance Upgrade for the Exam 255 and Exam 510 systems. Clemens Lieberwirth, CTO at Aim 3D: “The High Performance Upgrade comprises two optimization modules: Firstly, 'Input Shaping', which acts as a filter for the acceleration of the axes, increasing component quality at high travel speeds, and secondly, 'Extruder Pressure Control' for improved dosing and higher component quality.” The High Performance Upgrade is available for all existing systems on the market and on new systems from Aim 3D.

The integration of “input shaping” based on the industrial PLC control of the Exam 255 and Exam 510 systems was one approach of the High Performance Upgrade to enable higher assembly speeds for components and reduce vibrations. In input shaping, a bandpass filter is used on the control variable acceleration of the axes as a pilot control. This not only enables higher speeds in component assembly (assembly rate), but also produces significantly smoother component edges, as the oscillation of the axes is reduced.

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Date: 08.12.2025

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Improved extruder dosing with “Extruder Pressure Control”

The “Extruder Pressure Control” optimization module regulates the pilot control of the extruder. The module adapts the non-linear behavior of the screw extruder even better to the values specified by the slicer. This allows the extruder to respond more flexibly to speed changes in the print profile of a build job. At the same time, the extrusion quality is significantly improved: material buildup in the corners is reduced, which improves the edge sharpness of the components. In addition, gaps or cavities inside the component are avoided, which further improves the already high achievable densities of components from 3D pellet printing. Especially for applications with high-performance materials and filled materials in the aerospace sector, but also, for example, in media-carrying areas in the automotive industry, the optimized control of the extruder offers increases in component quality.

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