04.08.2025
3D Systems is unveiling several new solutions designed to change the way industries innovate. 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 precision, high mix, low volume applications such as motorsports components, furniture hardware, and electrical connectors. Additionally, 3D Systems will debut its first-to-market new module for its EXT Titan Pellet printers which delivers greatly improved process efficiency for a breadth of applications that require machining during post-processing. Furthermore, bolstering its pioneering work in investment casting, 3D Systems is announcing availability of the QuickCast Diamond build style, available in 3D Systems’ 3D Sprint software, to be used with its PSLA 270 projector-based technology, accelerating time to part-in-hand. The Company’s continued investment in R&D enables this diverse suite of new technologies and reinforces its dedication to empowering its customers to achieve transformative results.
High Throughput, Precision Manufacturing Solution for Plastics Parts
The increasing need for specialized industrial components and the adoption of flexible manufacturing technologies are driving the growth of high mix, low volume (HMLV) production. Traditional manufacturing methods, while effective for high volume production, face significant challenges when applied to HMLV manufacturing such as high costs and long lead times.
To address HMLV manufacturing needs, 3D Systems is introducing the Figure 4 135. Blending advanced material development with the power of its projector-based technology, this 3D printer provides the necessary agility and flexibility to efficiently meet the diverse and fluctuating demands of such manufacturing environments. By applying this solution, manufacturers can eliminate tooling and inventory management and reduce costs by multiple orders of magnitude. With extremely high out-of-the-box precision and very high stability, 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 significantly exceeds these standards making it highly 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 requiring accuracy and repeatability.
Electrical connectors are another great example of traditionally manufactured plastic parts using injection molding which requires tooling and long lead times. Conversely, additive manufacturing enables direct 3D-printed production-grade precision connectors with high fidelity, high thermal stress resistance, and cost-efficiency at high volumes. When applying the Figure 4 135 solution to this application, manufacturers can potentially save millions of dollars when designing and manufacturing hundreds to thousands of connector SKUs per year.
As part of this particular 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 (i.e., 0.4mm) 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 that require accuracy, heat resistance, durability, flexibility, and electrical safety.
The Figure 4 135 solution — both the printer and material — is available for immediate ordering.
Novel Solution Drives Significant Improvements in Process Efficiency
3D Systems’ EXT Titan Pellet systems are proven 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. Today, the Company announces a new module that is patent-pending scanning technology available for 3D Systems’ EXT 1070 Titan Pellet and EXT 1270 Titan Pellet printers which delivers greatly improved process efficiency for users.
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 seamlessly with EXT Titan control software. The module is planned to be available in the third quarter of 2025.
