KraussMaffei is introducing powerPrint Flex, a modular, robot-based system for large-format industrial 3D printing, which will be shown at Formnext in Hall 12.1, booth E119. Building on the closed powerPrint Plus platform, the new concept focuses on flexibility through configurable manufacturing cells. It combines the company's extrusion know-how with a scalable architecture, giving manufacturers broad freedom in design and material selection. Production cells can be scaled and tailored to specific project requirements.
Target applications range from designer furniture and thin-walled automotive parts to tooling for resin transfer molding. On the booth, a carbon fibre-reinforced polycarbonate rear diffuser for a sports car will be printed live, illustrating the capability to produce large, thin-walled parts with high rigidity and accuracy without tooling. The approach supports functional prototypes and design studies, enabling immediate design iterations, shorter development cycles and lower costs.
Modular cell concept and equipment
The standard configuration of powerPrint Flex integrates a Comau N-170 robot within the production cell, with multiple customization options available. The print bed measures 2500 x 2000 mm, can be heated up to 180 °C, and incorporates 16 vacuum zones for the printing plates. KraussMaffei’s in-house developed extruder, printCore 35-25, delivers high output rates from 30 to 70 kg per hour depending on the material feed system. With a maximum melting temperature of 400 °C, the system processes demanding fibre-reinforced thermoplastics and high-performance polymers, addressing requirements in automotive and aerospace, toolmaking and general industrial projects.
Control and integration
PowerPrint Flex uses the Sinumerik One system from Siemens to control its six-axis robot. This platform provides precise, dynamic and networked motion control. Thanks to the modular design, the system can be integrated into existing manufacturing environments and expanded with additional functions, such as rotary tables or milling centers. The result is a mature solution that is optimally tailored to the respective production process.
Support and services
KraussMaffei’s decades of expertise across plastics processing underpin its additive manufacturing strategy. The company’s systems are designed for industrialized 3D printing with high precision, consistent quality and scalable efficiency. Customers have access to technical expertise, solution-oriented consulting and a global service network. Support includes developing the business case and engineering customized additive manufacturing or hybrid production systems.
printCore - Extruder for industrial additive manufacturing
