Most Exciting Things We Found at Formnext 2025
Every year at Formnext you feel the pulse of where the industry is heading, and 2025 was no different. Walking the halls, a few applications genuinely stopped us in our tracks. They were clever, ambitious, and in some cases a little unexpected, which is exactly what makes this show so fun to cover. Here are the highlights that stood out to us this year.
Large-format AM pushed the boundaries of scale this year, and the CEAD and Faber Navalis collaboration was a perfect example of what is now possible. They showcased a fully 3D printed boat hull produced in a single weekend, built using an automated workflow and CEAD’s HDPro material to create tough, impact-resistant structures. The result was a 5.78-meter fishing vessel that looked surprisingly sleek given its size and the speed at which it was made. It was one of those classic Formnext moments where you catch yourself asking, “wait… this is actually printed?” and suddenly rethink what large-scale AM can do.
A similar excitement hit in aerospace when we stopped by the GE Catalyst turboprop. Nearly 30 percent of the engine is metal 3D printed through Colibrium Additive’s powder bed fusion systems, using high-performance alloys like nickel alloy 718. The real benefit comes from part consolidation, where components that once required many separate pieces can now be built as single optimized structures that are lighter, stronger and easier to assemble. These gains help the Catalyst reach one of the best power-to-weight ratios in its class and show how metal AM is moving firmly into flight-ready production.
Fashion showed up in a surprising way this year, and it was impossible not to stop for Alexander Wang’s 3D printed kitten heels. Produced by Hilos using Carbon’s DLS technology, the shoes pair a rigid printed heel with a soft multi-density lattice upper that gives them their structure and unexpected comfort. It was one of those Formnext moments where engineering and design click together perfectly, and judging by the reactions around the booth, I was not the only one surprised by how wearable they actually were.
We were especially intrigued by the work at the Rapid Liquid Print booth, where their gravity free process remains one of the most distinctive techniques in additive manufacturing. Instead of depositing material layer by layer in open air, the printhead moves through a gel-filled reservoir, allowing complex shapes to form without supports. This environment lets the material cure in place, so parts come out smooth, flexible and essentially ready to use. The team showed how a full-scale motorcycle seat can be printed in 392 minutes and a helmet liner in 165 minutes. It is a strong reminder of what this process is built for: fast, customized, end-use parts that traditional extrusion systems simply cannot produce.
It is a bird… it is a plane… it is an EOS drone, and it ended up being one of my favorite surprises at Formnext this year. We discovered it at the EOS booth, where the team showcased a bio-inspired drone designed to fly like a real bird while staying nearly undetectable. The entire system is produced on the EOS P 396 through selective laser sintering and prints in just 3 hours and 35 minutes using ALM PA 640 GSL, their reinforced polymer powder that keeps the structure lightweight, stiff and high-performance. It is a standout example of stealth-focused UAV design made possible by additive manufacturing, and seeing how naturally it moved was one of those moments where engineering and biology feel perfectly aligned.
Formnext 2025 brought together imagination, engineering and real-world production in a way that felt especially dynamic this year. Across mobility, aerospace, fashion and marine applications, these highlights offered a clear snapshot of where additive manufacturing is heading next. To see each one up close, our full video recap brings all of these technologies to life.
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