MUNICH, Germany, Oct 31, 2025 – KraussMaffei will showcase powerPrint Flex at Formnext in Frankfurt, Germany, from Nov. 18–21, 2025. The 3D printing solution is designed for producing large-format components and tooling. powerPrint Flex introduces a robot-based manufacturing setup that offers flexibility for different production environments. The system will be showcased at Hall 12.1 / Booth E119.
KraussMaffei’s powerPrint Flex system uses a robotic 3D printing setup designed for these applications. The system integrates KraussMaffei’s extrusion technology with a modular design, allowing manufacturers to adjust configurations for specific production requirements. powerPrint Flex supports a range of materials and enables scalable production cells tailored to customer needs.
A Thin-Walled Component in the Making
At Formnext, KraussMaffei will demonstrate its powerPrint Flex by printing a carbon fiber–reinforced polycarbonate rear diffuser for a sports car. The large-format 3D printing process enables rapid, tool-free production of lightweight, rigid components with precise geometry. This approach supports functional prototypes and design studies, allowing design changes, shorter development cycles, and lower costs.
In-House Developed Extruder: printCore 35-25
The standard powerPrint Flex configuration includes a Comau N-170 robot inside the production cell and can be customized. The print bed measures 2500 x 2000 mm,, heats up to 180 °C, and contains 16 vacuum zones for the printing plates. KraussMaffei’s printCore 35-25 extruder provides output rates of 30 to 70 kg/hour, depending on the material feed system. With a maximum melt temperature of 400 °C, the system processes fiber-reinforced thermoplastics and polymers.
Flexible Integration of the Robot into Modular Manufacturing Systems
powerPrint Flex uses the Sinumerik One system to control its six-axis robot. This control system enables precise, dynamic and networked motion control. powerPrint Flex can be integrated into existing manufacturing environments due to its modular design, and expanded with functions such as rotary tables or milling centers.
Hardware, Consulting, and Services
KraussMaffei develops 3D printing focused on precision, consistency, and scalable production. Customers benefit from technical expertise, application support, and a global service network. KraussMaffei also helps manufacturers to evaluate business cases and design customized additive or hybrid manufacturing systems.
Source: KraussMaffei
About KraussMaffei
KraussMaffei, headquartered in Parsdorf near Munich, Germany, is one of the world’s leading manufacturers of machinery and systems for producing and processing plastics and rubber. Founded in 1838, the company has more than 185 years of engineering and manufacturing expertise. Its portfolio includes injection molding machines, extrusion technology, reaction process machinery, additive manufacturing systems, and automation and digital solutions. KraussMaffei serves multiple sectors, including automotive, packaging, medical technology, construction, and electrical and electronic manufacturing. With about 4,200 employees, more than 30 subsidiaries, and over 10 production plants worldwide, the company maintains international presence supported by nearly 570 commercial and service partners. KraussMaffei reported annual revenue of approx. €1.25B in 2024 and has been part of Sinochem Holdings Corporation Ltd., one of the world’s leading chemical companies, since its acquisition.
About Formnext
Formnext, held each year in Frankfurt, Germany, is a international trade fair and conference for additive manufacturing and 3D printing technologies. The event brings together manufacturers, material suppliers, software developers, and end users from industries such as automotive, aerospace, tooling, medical technology, electronics, and consumer products. Established in 2015, Formnext has become a meeting place for the global additive manufacturing community. The event is organized by Mesago Messe Frankfurt GmbH, based in Stuttgart, Germany.