3D Systems Debuts Next-Gen Solutions at Formnext 2025

3D Systems shares several new products for its Stereolithography (SLA) portfolio it will showcase at Formnext 2025. The Company is introducing the SLA 825 Dual, its high-throughput SLA solution with a larger build volume and productivity enhancements for automotive, Formula 1, aerospace and space applications.

Additionally, 3D Systems is showcasing ArrayCast, its solution for investment casting that eliminates the need for tooling. The Company enhanced its SLA materials portfolio with Accura SbF and Accura Xtreme Black to address casting and prototyping applications.

SLA 825 Dual for Large-Frame Stereolithography

3D Systems’ new SLA 825 Dual is the Company’s advanced large-frame SLA printer. With a new, 20% larger build volume of 830x830x550 mm, dual-laser architecture, and simplified user workflow, the SLA 825 Dual will target high-performance industries such as transportation and motorsports, and aerospace and defense.

The SLA 825 Dual is available for immediate ordering, with the first shipments planned to begin in December 2025.

ArrayCast Optimizes Foundry Workflows

ArrayCast is immediately available to 3D Systems’ customers as an add-on through its 3D Sprint software. Image courtesy: 3D Systems.

3D Systems introduces ArrayCast, a new software that allows users to create customized casting trees, with configurable runners, sprues, and end effectors for their workflow. Key benefits include:

• Faster production cycles by digitally assembling casting trees before printing begins
• Reduction in manual labor hours through use of fully assembled, 3D-printed casting trees—
• Consistency and repeatability with a digital workflow that minimizes human error and ensures every tree meets exact specifications 

ArrayCast is immediately available to 3D Systems’ customers as an add-on through its 3D Sprint software, targeting the Company’s polymer printing platforms. 

Accura SbF for Casting Metals

3D Systems is introducing an enhancement to its Investment Casting portfolio, Accura SbF. The Company’s latest SLA casting resin has no detectable Antimony, suitable for casting a variety of ferrous and non-ferrous high-performance metals, such as Nickel-based superalloys and Titanium. Accura SbF patterns have high modulus.

Accura SbF is available for immediate ordering. 

Accura Xtreme Black

At Formnext 2025, 3D Systems is showcasing Accura Xtreme Black, a high-performance prototyping resin. It offers durability for assemblies such as snap-fit components, enclosures, and consumer electronics. Combining Accura Xtreme Black with 3D Systems’ SLA technology can serve as an alternative to CNC machining of thermoplastics such as ABS. Its deep black color is intended to replicate the aesthetics of molded production parts. Accura Xtreme Black is a multi-functional resin for SLA. Accura Xtreme Black is available for immediate ordering.

“These next-generation additions to our Stereolithography portfolio will help catalyze our customers’ innovation,” says Marty Johnson, vice president of product and technical fellow, 3D Systems. “These technologies that include our new SLA printing platform and new build style for our QuickCast offering enhance our industry-leading solutions for polymer printing.”

3D Systems will feature these products in its booth (Hall 11.1, Booth D11) at Formnext 2025 (November 18-21 in Frankfurt, Germany) as part of its full portfolio of solutions for polymer and metal additive manufacturing.

Sources: Press materials received from the company and additional information gleaned from the company’s website.