Farsoon chases EOS on beam shaping for metal PBF in FS350M-4 system

Following EOS’s footsteps, Farsoon introduced Beam Shaping Technology to its FS350M-4 system. This innovation enables laser spots to be dynamically formed into various shapes, such as ring-shaped, point-ring-shaped, or fully customizable configurations tailored to specific application requirements. When combined with high-power lasers and optimized scanning strategies, this technology significantly enhances printing quality and efficiency for materials like stainless steel, aluminum alloys, and titanium alloys, achieving part densities exceeding 99.95%.​

Farsoon vs EOS

Last year, metal additive manufacturing market leader EOS has partnered strategically with nLIGHT to integrate beam-shaping technology into its metal AM systems. nLIGHT’s programmable AFX laser offers seven different beam profiles in a single laser, ranging from an 85-micron spot size for maximum precision contours to a 210-micron ring profile for faster printing, improved process stability, and reduced soot and spatter. This collaboration aims to make beam shaping and light engine optimization capabilities available digitally, enabling customers to access different beam profiles via EOS software to activate higher productivity printing.

AMCM, an EOS Group company focused on customized AM solutions, has made the programmable AFX laser available in its metal AM systems. It plans to make AFX-enabled machines available to customers in late 2024. Earlier this month, Aerospace Metal AM service provider Sintavia introduced the AMCM M290-2 FLX 3D printer with the nLIGHT AFX beam-shaping fiber system, making it the first machine deployed to a North American customer with this cutting-edge technology.

Via Beam Shaping Technology, Farsoon offers several key advantages over traditional Gaussian spots, including unmatched printing speed with melt pool width increases of 50%–100% and build volume rates increased by over 2.5 times without compromising part quality. It also reduces spatter, minimizing powder contamination and porosity in-built parts, enables precision manufacturing of intricate features such as thin-wall structures, enhances thermal stability by lowering temperature gradients to improve process stability and part consistency, and is ideal for high-thermal conductivity materials, including copper alloys.​

This technology is poised to transform consumer goods, mold manufacturing, 3C electronics, aerospace, and precision casting industries. As Farsoon’s flagship medium-sized metal production system, the FS350M-4 platform equipped with Beam Shaping Technology delivers unparalleled performance for industrial additive manufacturing. Featuring quad 1000-watt lasers and a build volume of 433 × 358 × 400 mm, this system is engineered to enhance productivity and manufacturing turnover rates significantly. Integrating Beam Shaping Technology ensures superior print quality, faster build speeds, and exceptional material utilization, making it an ideal solution for high-volume serial production across various industries.​

Farsoon plans to integrate Beam Shaping Technology into larger metal platforms, including the FS621M, FS811M, and meter-scale systems.

FS1521M-U now supports 32 lasers

In parallel, Farsoon introduced the FS1521M series in 2023, featuring 16 lasers and a standard-build cylinder measuring 1530 mm × 1530 mm × 850 mm (FS1521M). The series also offers an extended high-cylinder build volume of 1530 mm × 1530 mm × 1650 mm (FS1521M-U), designed for industrial-scale serial production of large-format metal parts. Since its launch, the FS1521M series has been widely adopted by industrial customers worldwide.

Building on this foundation, the FS1521M-U now supports up to 32 × 500W fiber lasers, offering unprecedented efficiency, scalability, and cost-effectiveness. This enhancement significantly accelerates high-quality mass production, reducing material waste and improving the overall economics of metal additive manufacturing.​

The FS1521M-U’s substantial build volume of 3,862 liters, combined with advanced multi-laser overlap algorithms, ensures consistent mechanical properties across the entire build area, minimizing variations—a critical advancement for serial production. The system’s next-generation powder and airflow management features include four overflow and four recycling powder hoppers, supporting up to four powder recycling units with a combined processing rate of 360L/h. Its dual powder cartridges and parallel dual powder conveying units ensure a steady, robust powder supply for large-scale parts, delivering a more efficient and seamless production operation. Additionally, the dual-layer airflow system with permanent filtration ensures uniform smoke removal, which is crucial for large-span prints, while automated powder handling improves safety and efficiency.​

The FS1521M series, including both the standard FS1521M and the high-cylinder FS1521M-U, offers multiple circular or square build volume configurations. This flexibility optimizes powder usage, reduces costs, and enhances adaptability for various industrial applications. The updated FS1521M series marks a significant milestone in large-scale industrial metal 3D printing, combining large-format scalability, high-speed multi-laser efficiency, and enhanced cost-performance solutions.​