Formnext 2024 was a great opportunity to find companies that have introduced new and innovative additive manufacturing (AM) solutions, specifically the ones that focus on the integration of AM in producing end-use parts. When it comes to FDM and metal technologies, I was curious to learn if there was something new to see, or if most of the solution providers were offering ‘more of the same’. After all, how much more innovative can you be with two technologies that have been around for more than 30 years.
Eventually, two AM companies, one FDM, and one large-scale metal AM system solution providers caught my eye – OMNI3D from Poland, and Wayland Additive from the UK. What makes these two companies stand out compared with similar companies in the industry?
OMNI3D: A Polish Leader in Industrial FDM Solutions
The company has been carving its place in the additive manufacturing (AM) landscape with its focus on large-format industrial-grade material extrusion solutions since 2013. At Formnext 2024, the company showcased its commitment to developing an end-to-end ecosystem designed to meet the needs of demanding industries such as aerospace, automotive, maintenance, and manufacturing.
What makes OMNI3D unique is its holistic approach to AM. Rather than focusing solely on 3D printers, the company offers a complete package, including:
Advanced software tools: Streamlining the design-to-production workflow.
A robust 3D printer portfolio: Industrial large-format systems capable of processing high-performance and engineering-grade materials.
Diverse material options: Polymers ranging from standard thermoplastics to high-temp and specialty materials.
Supporting equipment: Dryers, washing machines, and post-processing solutions.
Service and consultation packages: Helping customers maximize ROI by identifying applications and optimizing the use of their technology.
Engineering and 3D printing services: Extensive experience helping organizations of all sizes, from Fortune 500 companies to smaller enterprises, adopt and deploy Omni3D solutions within their production and engineering workflows.
OMNI3D's dedication to pushing the boundaries of FDM technology caught the attention of many attendees at Formnext, particularly those seeking large-format mid-range yet industrial-grade solutions. Their ability to integrate innovation into long-standing FDM technology underscores their status as a significant player in this segment.
OMNI3D industrial mid-range product portfolio. Image source: OMNI3D.
In the highly competitive landscape of FDM system manufacturers, OMNI3D has strategically carved out a unique niche by offering tailored solutions for specific industries and applications. Their approach centers on a deep understanding of customer needs, challenges, and how Additive Manufacturing (AM) technology can provide tangible benefits.
Recognizing the potential of additive manufacturing (AM) within the railway industry, OMNI3D has developed specialized solutions to address the unique challenges faced by rail operators. These include maintaining older trains with hard-to-source parts and innovating lightweight components for modern high-speed trains. Backed by extensive experience not only in AM hardware, software, and materials, but also in relevant certifications for railway applications including post-processing, certified adhesives, and paints, OMNI3D provides comprehensive training and support to ensure seamless AM integration. OMNI3D’s tailored solutions for the railway industry help implementing:
Digital Parts Inventory: By digitizing the inventory, railway companies can store virtual designs rather than physical parts, reducing storage costs and enabling rapid, on-demand manufacturing.
Lightweight Components: AM allows for the production of optimized, lightweight parts that enhance energy efficiency and performance.
Legacy Part Production: For older train models, AM offers a cost-effective way to produce discontinued or low-volume parts.
End-to-End Solutions: OMNI3D integrates advanced software, customized 3D printing systems, dedicated materials, and optimized workflows to ensure seamless production of high-quality end-use parts.
By leveraging AM, railway companies can reduce downtime, minimize inventory costs, and extend the life of their fleets. At the same time, the ability to produce innovative, lightweight components supports the development of next-generation trains, aligning with the industry's shift towards sustainable and efficient transportation solutions.
After an intensive research and development process, OMNI3D has introduced a tailored solution designed specifically for railway companies. This comprehensive production package addresses the industry's unique challenges, enabling railway operators to integrate Additive Manufacturing (AM) seamlessly into their maintenance and manufacturing processes.
The key components of OMNI3D’s solution are:
Large-Scale 3D Printing Systems: OMNI3D offers dedicated, industrial-grade FDM printers capable of producing large and complex components for railway applications. These systems are designed to handle high production volumes while ensuring precision and repeatability, making them ideal for manufacturing end-use parts and on-demand replacements.
Certified Materials for Safety Compliance: The solution includes materials certified to meet stringent European fire safety standards, a critical requirement for parts used in railway interiors and exteriors. These materials combine mechanical strength, heat resistance, and durability, ensuring they meet the operational demands of the railway industry.
Comprehensive Post-Processing and Finishing: OMNI3D has developed a fully certified post-processing workflow that ensures parts meet the aesthetic, functional, and safety standards required by railway operators. This includes advanced surface finishing, painting, and quality assurance processes to deliver production-grade parts ready for deployment.
A complete solution of 3D printers and materials. Image source: OMNI3D.
With over 65,000 train wagons in Europe alone—many of them legacy models requiring extensive maintenance—the opportunity for Additive Manufacturing (AM) in this sector is immense. The variety of parts that can be 3D printed is vast, ranging from lighting elements, tables, and armrests to seats and other interior components.
End-use parts production of internal wagon components. Image source: OMNI3D.
At Formnext 2024, OMNI3D showcased its latest achievements, emphasizing its targeted approach to implementing AM solutions across diverse industries. Instead of taking the conventional path of competing solely on pricing, OMNI3D has positioned itself as an "application solution provider"—a move that has successfully set the company apart in the highly competitive FDM market.
OMNI3D sample parts at Formnext 2024. Image source: OMNI3D.
Wayland Additive: A UK Pioneer in Large-scale Metal AM
It is widely recognized that metal Additive Manufacturing (AM) is gaining momentum, with leading industrial manufacturers already integrating digital manufacturing into their operations. However, advancing to the next level—producing large-scale metal components or small batches of precision parts—demands technology capable of meeting high manufacturing standards. This includes enabling a wide range of materials while maintaining user-friendly and efficient processes.
Formnext 2024 provided an excellent platform to explore groundbreaking metal AM companies and to understand their visions for the future. Among them was Wayland Additive, a UK-based pioneer specializing in innovative electron beam (eBeam) AM technology. The company’s flagship product, the Calibur3 system, is powered by their proprietary NeuBeam technology, which sets them apart in the AM market.
NeuBeam technology offers significant advantages over traditional electron beam and laser-based processes, presenting a transformative approach to industrial-grade metal AM.
Wayland Additive booth at Formnext 2024. Image source: Wayland Additive.
What makes the company’s technology unique compared with similar solutions in the industry?
Neutral Beam Process: Unlike conventional eBeam systems that use a charge-carrying process, NeuBeam neutralizes the charge, making it more a more stable process and and therefore less restrictive in terms of materials and applications.
Material Flexibility: Enables the use of a wider range of materials, including those that are challenging for laser or traditional eBeam systems, such as high-performance alloys.
Improved Part Quality: Produces parts with reduced residual stresses and better mechanical properties, thanks to its temperature and charge management.
Simpler Overall Process: Offers less complexity in post-processing compared to traditional powder bed fusion methods.
Formnext 2024: Variety of materials – wider spectrum of applications
Wayland Additive's NeuBeam technology is purpose-built for demanding industrial applications across sectors such as aerospace, defense, medical, and energy. The system excels in producing parts with complex geometries, using high-performance materials, and meeting large-scale production requirements.
With a stable, reliable, and flexible eBeam PBF process, the Calibur3 delivers fully dense parts and supports an impressive selection of advanced materials. These materials often exceed the compatibility range of traditional eBeam or laser PBF systems, making Wayland Additive’s technology a powerful tool for high-end applications.
At Formnext 2024, Wayland Additive unveiled several examples of how its technology is being utilized for cutting-edge applications:
Medical Implants: Custom-designed elements created from certified materials suitable for end-use medical parts.
Rocket Nozzle: A large-scale, additively manufactured skinned rocket nozzle mockup, fabricated without support structures to highlight design flexibility. Material type: Ti64.
Turbine Blade: A highly complex geometry, achievable exclusively through additive manufacturing, showcasing precision engineering and material performance.
All parts are printed with Ti64 powder.
Open system with wide variety of advanced materials. Image source: Wayland Additive.
Scaling Metal AM for High-Value Applications
Wayland Additive is dedicated to addressing the limitations of conventional metal AM systems. By leveraging its innovative NeuBeam technology, the company aims to make metal AM more accessible and practical for high-value industrial applications.
The company's strategy aligns with the needs of forward-thinking manufacturers—those who have already integrated digital manufacturing into their design and production workflows and are now seeking the next step to scale production. With a focus on efficiency, flexibility, and material versatility, Wayland Additive is uniquely positioned to empower its users to achieve greater productivity and profitability.
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