In the rapidly evolving world of industrial additive manufacturing (AM), Formnext 2025 emerged as a pivotal event, showcasing breakthroughs that are transforming how industries approach production. Held in Frankfurt, this 10th-anniversary edition highlighted innovations in Powder Bed Fusion – Electron Beam (PBF-EB) and hybrid systems, pushing the boundaries of speed, scale, and efficiency beyond traditional prototyping. These advancements are crucial for sectors like aerospace, medical, and automotive, where high-precision parts at industrial volumes are in demand. At LAVA3DP, our expert 3D printing services leverage such cutting-edge technologies to deliver scalable solutions—contact us today to explore how we can accelerate your manufacturing processes.
PBF-EB technology, which uses an electron beam to melt metal powders in a vacuum, has long been valued for its ability to produce dense, stress-free parts with excellent mechanical properties. Unlike laser-based systems, PBF-EB operates at higher temperatures, reducing residual stresses and enabling support-free builds for complex geometries. Hybrid systems, meanwhile, integrate additive processes with subtractive methods like CNC milling, offering versatility for finishing and multi-material applications. Formnext 2025 spotlighted three key innovations in these areas, each redefining manufacturing by enhancing productivity, reducing costs, and expanding scalability.
Innovation 1: Wayland Additive’s Calibur3 – Revolutionizing PBF-EB Stability and Versatility
One standout PBF-EB innovation at Formnext 2025 was Wayland Additive’s Calibur3 system, which employs the proprietary NeuBeam process to address longstanding challenges in electron beam melting. This charge-neutral technology neutralizes the electron beam, eliminating powder scattering and enabling stable, high-speed melting without the need for extensive post-processing. With a build volume of 300 x 300 x 450 mm and a 5 kW electron beam, the Calibur3 supports layer thicknesses of 50-90 µm and bed temperatures up to 1000°C, making it ideal for processing reflective or crack-prone alloys like titanium and nickel superalloys.
The system’s open architecture allows for material agnosticism, broadening its application from aerospace components to medical implants. Compared to traditional EBM systems, NeuBeam reduces residual stresses by up to 90%, cutting post-heat treatment times and boosting overall productivity. At Formnext, Wayland demonstrated how this innovation scales production, with melt rates supporting faster builds—up to 50% quicker in some cases—while maintaining part integrity. For manufacturers seeking to transition from prototypes to series production, the Calibur3 represents a game-changer in industrial 3D printing speed and scale.
To visualize the scalability, consider this comparison of build volumes across leading PBF-EB systems:
This chart highlights how the Calibur3 offers superior volume for larger parts, enhancing manufacturing efficiency. If you’re exploring PBF-EB for your projects, LAVA3DP‘s 3D printing services can integrate similar technologies—get a free quote now!
Innovation 2: Colibrium Additive’s Spectra M – Compact Power for High-Speed PBF-EB Production
Colibrium Additive, formerly GE Additive, unveiled the Spectra M at Formnext 2025 as a compact yet powerful EB-PBF solution tailored for smaller build volumes without sacrificing performance. With a cylindrical build envelope of Ø270 x 430 mm and a 4.5 kW beam power, this system is optimized for materials like Ti6Al4V Grades 5 and 23, commonly used in orthopedic implants and energy sector components.
What sets the Spectra M apart is its reported 60% productivity boost over previous models, achieved through advanced EBMControl software that enables Point Melt and Plate Free technologies for support-free builds and faster layer processing. This innovation addresses the demand for entry-level industrial AM systems that scale efficiently, reducing turnaround times and operational costs. At the event, Colibrium showcased how the Spectra M accelerates manufacturing speed, with high melting capacity allowing for denser parts in less time—ideal for serial production in regulated industries.
Integrating features like Powder Supports, the system minimizes material waste and enhances scalability, producing over 50,000 implants annually in similar setups. For global audiences, this means more accessible PBF-EB technology, redefining how small-to-medium enterprises approach large-scale additive manufacturing. Ready to boost your production speed? LAVA3DP offers customized 3D printing consultations—reach out today.
Innovation 3: Imes-icore’s CoriTec Mythos – The Future of Hybrid AM Systems
Shifting to hybrid systems, Imes-icore’s CoriTec Mythos stole the show at Formnext 2025 as the world’s first fully automated hybrid manufacturing platform, blending additive coating (PEM) with 5-axis subtractive milling. Designed primarily for dental applications, this system produces multi-colored, multi-material restorations like crowns and bridges with unparalleled precision and aesthetics.
The hybrid approach combines additive deposition for organic shapes with subtractive grinding for superior surface finishes, eliminating manual interventions and reducing production times by up to 40% in complex workflows. With 5-axis technology, it handles true 3D structures, scaling from prototypes to high-volume output in a single machine. Formnext attendees saw demonstrations of its seamless integration, highlighting how hybrid systems like this redefine manufacturing scale by merging AM’s flexibility with CNC’s accuracy.
Beyond dental, the CoriTec Mythos inspires broader industrial applications, such as in aerospace for hybrid tooling. Its automation features cut labor costs and errors, making it a scalable solution for global manufacturers. As AM evolves, hybrids like this bridge the gap to full industrialization.
These innovations from Formnext 2025—Wayland’s Calibur3, Colibrium’s Spectra M, and Imes-icore’s CoriTec Mythos—illustrate how PBF-EB and hybrid systems are accelerating manufacturing speed (with gains up to 60%) and scaling production volumes. They reduce waste, enhance material versatility, and lower barriers to adoption, as seen in trends toward multi-material and AI-optimized workflows. For businesses worldwide, this means faster time-to-market and cost savings.
At LAVA3DP, we’re committed to bringing these advancements to your doorstep through our comprehensive 3D printing services. Whether you need PBF-EB prototypes or hybrid production runs, our team is here to help—schedule a consultation today and redefine your manufacturing capabilities.
FAQs
1. What are the advantages of PBF-EB in industrial 3D printing?
PBF-EB, or Powder Bed Fusion – Electron Beam, offers high-speed melting, reduced residual stresses, and support-free builds for complex metal parts, making it ideal for aerospace and medical applications. At LAVA3DP, our 3D printing services utilize PBF-EB for efficient, scalable production.
2. How do hybrid additive manufacturing systems improve production efficiency?
Hybrid systems combine additive deposition with subtractive machining, enabling precise finishing and multi-material capabilities in one workflow, reducing time and costs. LAVA3DP provides hybrid 3D printing solutions to streamline your manufacturing processes.
3. What types of materials can be used in PBF-EB 3D printing services?
Common materials include titanium alloys like Ti6Al4V, suitable for high-strength parts. Our experts at LAVA3DP handle a wide range of metals in PBF-EB, ensuring custom solutions for your needs.
4. How does LAVA3DP ensure quality in 3D printing services?
We adhere to ISO standards with advanced monitoring and post-processing, delivering precise, reliable parts. Contact LAVA3DP for quotes on our quality-assured industrial 3D printing services.
5. What is the cost of hybrid 3D printing services at LAVA3DP?
Costs vary by project complexity and volume; we offer competitive pricing with free consultations. Visit lava3dp.com to learn more about our affordable hybrid additive manufacturing options.