FormNext 2024 – Printing Overhangs Without Support Structures (Patreon)

A highlight of FormNext this year was FlipoQ, a startup from TU Darmstadt with an impressive goal: making FDM printing of complex structures possible without support structures.

How do they do it? By introducing a fourth axis that rotates during printing. On this axis, they print a Grid that acts as a base layer. But here’s where it gets really exciting—the printer can rotate the print bed a full 180 degrees! This clever feature allows overhangs, which usually require supports, to be printed as if they were lying flat on the bed.

Who would have thought we’d see a printer that can print from both sides of the bed?

Another unique feature is their custom-built micro pellet extruder. This extruder features a 6mm wide screw and weighs around 600g. The material used isn’t standard filament; instead, it’s pellets infused with wood shavings. This allows the printed pieces to feel remarkably like real wood—something that would be impossible with filament, as it would be too brittle for such applications.

All in all, I was impressed by what Jens Butzke and his team have accomplished. I’m eager to see how this project and the company around it evolve in the future. Currently, their goal is to bring this printer to the B2B market, offering industrial clients a faster, more affordable alternative to slow and expensive 5-axis 3D printers.