Krauss Maffei's Powerprint Flex: A Revolution in 3D Printing

Robot plus extruder Industrial 3D printing with a flexible system innovation

2025-11-04 Source: Krauss-Maffei 2 min Reading Time

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At Formnext 2025, Krauss Maffei will present the Powerprint Flex together with a matching tool — a modular 3D printing system designed for relatively large components.

Here you can see the newly developed, robot-assisted 3D printing system Powerprint Flex from KraussMaffei. It will be the centerpiece of the Parsdorf-based company’s appearance at Formnext 2025. Learn more here...(Source: Krauss-Maffei) — Here you can see the newly developed, robot-assisted 3D printing system Powerprint Flex from KraussMaffei. It will be the centerpiece of the Parsdorf-based company’s appearance at Formnext 2025. Learn more here...
(Source: Krauss-Maffei)

At Formnext 2025, Krauss Maffei will present the Powerprint Flex together with a matching tool — a modular 3D printing system designed for relatively large components.

Following the success of its enclosed 3D printing system Powerprint Plus, Krauss Maffei is now focusing on maximum flexibility. This is what the robot-assisted production cell Powerprint Flex is designed to deliver, according to the company’s preview of Formnext 2025, which will take place from November 18 to 21 in Frankfurt am Main.

The motivation behind developing the new system lies in the growing diversity of projects in additive manufacturing with plastics. The range of applications now extends from designer furniture to automotive components with thin walls and molds for resin transfer molding (RTM). According to Krauss Maffei, industrial 3D printing is increasingly conquering sectors with very different requirements — and Powerprint Flex is designed to support this trend.

The system is described not only as flexible but also as compact and highly efficient. It combines Krauss Maffei’s established extrusion technology with a modular system architecture. This setup gives users extensive freedom in both part design and material selection. Moreover, Powerprint Flex production cells can be scaled and customized to individual application needs.

At the Frankfurt trade fair, Krauss Maffei plans to demonstrate the production of a rear diffuser for a sports car, made from carbon fiber-reinforced polycarbonate (PC) — a CFRP material with a thermoplastic matrix.

A thin-walled component will be printed at Formnext

The system enables fast, tool-free production of large and thin-walled parts that are both rigid and precise — ideal for functional prototypes and design studies, according to Krauss Maffei. This allows design modifications to be implemented immediately, shortening development times and reducing costs.

The standard configuration of the Powerprint Flex includes the production cell and a Comau N 170 robot, with various customization options available. The print bed measures 2,500 × 2,000 mm and can be heated up to 180 °C, featuring 16 vacuum zones for securing the print plates.

At the core of the system is the Printcore 35-25 extruder, developed in-house by Krauss Maffei, which delivers 30 to 70 kilograms of polymer melt per hour, depending on the feeding system used.

The Printcore 35-25 extruder, specially developed by KraussMaffei, achieves output rates of 30 to 70 kilograms per hour. It forms the heart of the new Powerprint Flex 3D printing cell.(Source: Krauss-Maffei) — The Printcore 35-25 extruder, specially developed by KraussMaffei, achieves output rates of 30 to 70 kilograms per hour. It forms the heart of the new Powerprint Flex 3D printing cell.
(Source: Krauss-Maffei)

With a maximum melt temperature of 400 °C, the system can also process high-performance fiber-reinforced polymers, the company notes. The 6-axis robot is controlled by a Siemens Sinumerik One system, and the entire setup can be seamlessly integrated into existing production lines.

It can also be expanded with additional modules such as rotary tables or a milling center, making it suitable for applications in the automotive, aerospace, and toolmaking industries — to name just a few.

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