3D Systems Offers Application-Specific Solutions at RAPID + TCT

3D Systems is unveiling several solutions. At RAPID + TCT 2025, the company will showcase its Figure 4 135 3D printer and Figure 4 Tough 75C FR Black material that form the foundation of its cost-effective additive manufacturing solution for high-mix, low-volume applications such as motorsports components, furniture hardware and electrical connectors.

3D Systems will debut its module for its EXT Titan Pellet printers, which delivers process efficiency for applications that require machining during post-processing. Bolstering its work in investment casting, 3D Systems is making available of the QuickCast Diamond build style, available in 3D Systems’ 3D Sprint software, to be used with its PSLA 270 projector-based technology.

The need for specialized industrial components and the adoption of flexible manufacturing technologies are driving growth of high-mix, low-volume (HMLV) production. To address HMLV manufacturing needs, 3D Systems is introducing the Figure 4 135.

Manufacturers can eliminate tooling and inventory management and reduce costs by multiple orders of magnitude. The Figure 4 135 solution is ideal for manufacturing industries where a process capability index (CpK) of at least 1.33 or above (depending on part geometry and feature size) is required for critical processes.

The Figure 4 135 exceeds these standards making it reliable for precision applications where a manufacturer is replacing or supplementing injection mold tooling including furniture components such as custom assemblies that require special design considerations for low-volume furniture production, medical components requiring biocompatible material and precision, and low volume consumer electronics.

As part of this solution, 3D Systems is introducing Figure 4 Tough 75C FR Black. This tough, flame-retardant material is recognized by UL with a UL94 V0 rating at thin wall thickness and a Relative Thermal Index (RTI) for long-term electrical of 150°C and mechanical use of 130°C. This makes it ideally suited for applications such as appliances, consumer electronics and automotive.

The Figure 4 135 solution—both the printer and material—is available for immediate ordering.

3D Systems’ EXT Titan Pellet systems are made for production applications including patterns, molds, tooling, jigs, fixtures, end-use parts and full-scale prototypes for industries such as foundry, automotive, aerospace and defense, and consumer products.

The company announces a new module that is scanning technology available for 3D Systems’ EXT 1070 Titan Pellet and EXT 1270 Titan Pellet printers which delivers improved process efficiency for users.

• Part Solidity Optimization: This new module optimizes the extrusion flow rate in real time.
• Print Bed Mapping: Print bed leveling can be a critical step to avoid print failure when printing large format parts. This module scans the print bed in under 60 seconds and provides a numeric height map from which operators can determine if leveling is necessary and make precise adjustments where needed.

This new module will be standard on new EXT Titan Pellet systems equipped with the optional milling spindle toolhead and the hardware can be field installed on existing machines, integrating with EXT Titan control software. The module is planned to be available in the third quarter of 2025.

Investment casting, a technique integral to the manufacturing of complex components such as aircraft turbine blades, involves pouring molten metal into ceramic molds formed from sacrificial patterns.

The company is enhancing the performance of QuickCast, making the QuickCast Diamond build style available with 3D Systems’ PSLA 270. This projector-based stereolithography (SLA) printer combines high-speed production with part quality and mechanical stability.

“Innovation is in our DNA,” sys Dr. Jeffrey Graves, president and CEO, 3D Systems. “Our historic R&D surge in 2024 yielded dozens of polymer and metal products, all driven by a rising demand to address a number of applications using additive manufacturing. Now, we're commercializing these advancements, such as the Figure 4 135, which dramatically reduces costs and boosts throughput for many high-mix, low-volume applications."

At RAPID+TCT 2025

3D Systems will showcase these innovations alongside its full application-centric solution portfolio in its booth (#3201) at RAPID + TCT 2025 to be held April 8-10 in Detroit, MI.

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