EOS unlocks 50% higher productivity with P3 NEXT

EOS, a pioneer of selective laser sintering (SLS) and one of the leading industrial  3D printing companies operating today, has remained in its dominant position in part by continuing to expand its product offering and improve its solutions based on the evolving needs of adopters. One of the company’s latest systems, the EOS P3 NEXT, is a perfect example of how the German company continues to innovate and refine its technologies as the industry matures. 

The EOS P3 NEXT, introduced in November 2024, is a midframe polymer SLS production system that builds on the successes of the company’s preceding SLS solutions while also introducing a host of upgrades and new features that unlock significantly higher levels of productivity—as much as 50%—and greater value. In marketing the machine, EOS has been vocal about how the new platform was developed in response to customer requests and feedback.

“Customers highlighted the need to significantly decrease the total cost of ownership (TCO), improve the recyclability rate of materials and increase machine utilization,” explains Virginia Palacios, Chief Business Officer, Polymers at EOS. “They also sought a complete solution for powder management while maintaining high quality production and providing more control to adjust applications.”

Tackling productivity and TCO

In developing the EOS P3 NEXT, EOS engineers tackled these customer wants through the integration of new software functions and hardware tweaks. On the software front, Palacios explains how upgrades were central to enabling greater productivity through higher machine utilization and overall process efficiency.

She says: “The major productivity enhancements stem from new hardware controls that accelerate heating time, recoating and enable hot swap functionality. Software changes contribute significantly by improving process control, material parameters and system connectivity, including the addition of new dashboards for monitoring machine availability.”

On the hardware front, the EOS P3 NEXT includes a number of changes, from an overhauled PLC architecture, to upgraded heating lamps, to a new build frame. Palacios also reveals that the machine is equipped with a built-in nitrogen generator, which facilitates “hot swaps” and minimizes time between 3D print jobs. Compared to the EOS P 396, an SLS system with the same build volume of 340 x 340 x 600 mm, the new model has a more compact footprint thanks in part to an integrated monitor.

All these upgrades and changes have resulted in a system that delivers on all of EOS customers’ requests. Specifically, the EOS P3 NEXT has increased machine utilization rates (up to 90%), is has improved material efficiency (with up to 80% material reusability depending on the material) and has a total cost of ownership (TCO) as much as 30% lower than previous hardware models. 

Of course, the three selling points are all interconnected. As Palacios says: “The lower TCO is driven by higher machine utilization enabled by hot swap functionality, improved productivity and higher material refresh rates.” This hardware is also complemented by automated solutions like powder mixing and automatic unpacking, which reduce the need for labor and also contribute to a more attractive TCO.

Applications unlocked

The new SLS platform is a versatile solution and has applications in the production of medical equipment, eyewear, tooling and more. Palacios highlights that the machine could be particularly beneficial for high-mix service providers as well as for food-contact or direct-in-mouth printed applications like custom splints to manage bruxism (teeth grinding). “Some notable applications include food-contact products that were previously not feasible and are now unique in the market,” she says. “Additionally, direct printing of in-mouth products on a powder-based system with certified products is a first in its market.”

These new SLS applications are made possible through materials brought to market by EOS, including biocompatible powders like PA 2201, a pigment-free nylon 12 powder suitable for medical applications that can also be approved for contact with food.

“The EOS P3 NEXT allows us to produce applications for the regulated medical market within a fully certified production environment, ensuring we meet both quality and compliance benchmarks,” Jay Dinsmore, Executive Vice President of AM service ADDMAN. “As the workhouse technology for our new Health Excellence Additive Lab (HEAL) Center launching in Florida in January 2025, the EOS P3 NEXT will empower us to deliver unmatched quality and cost-effectiveness for our medical manufacturing partners, reinforcing our commitment to excellence in this critical industry.”

High-reuse powders

Beyond a growing list of possible applications for the EOS P3 NEXT, EOS’s sister company, Advanced Laser Materials (ALM) has also introduced additional materials optimized for reusability. In particular, the new ALM PA 950 HD powder can deliver up to 80% material reusability on the P3 NEXT, while EOS’ PA 2220 HighReuse powder has a 70% reuse rate. It goes without saying that being able to maximize powder usage has both ecological and economic benefits. “Increased sustainability is achieved through the use of highly recyclable materials that significantly reduce waste, carbon-reduced materials that lower energy consumption during production, and improved machine utilization that contributes to overall environmental efficiency,” Palacios elaborates.

ALM PA 950 HD, which was also launched at Formnext 2024, is a customized ALM powder with the highest reuse potential. The black 3D printing material (colored uniformly using a special mixing technique) is based on a stabilized polymer formulation that promotes consistent viscosity, even after being exposed to the heat of the SLS process multiple times. According to EOS, the best reuse rates can be achieved with ALM PA 950 HD using the right parameters, like using 9% nesting density, and ensuring proper powder handling. 

Overall, EOS’ new P3 NEXT platform and expanding materials range pushes SLS 3D printing further into the industrial sphere, allowing a variety of users—from medical labs to high-mix 3D printing services—to benefit from greater productivity, better machine usage and ultimately higher value production.

This article was published in collaboration with EOS.