3D Systems announced new additions to its stereolithography (SLA) product lineup that it will present at Formnext 2025. The company introduced the SLA 825 Dual, a high-throughput SLA system with a larger build volume intended for automotive, motorsports, aerospace and service bureau applications.
3D Systems also introduced ArrayCast, a solution for investment casting that removes the need for tooling and allows engineers to create casting patterns without upfront tooling requirements. In addition, the company expanded its SLA materials portfolio with Accura SbF and Accura Xtreme Black to support casting and prototyping applications.
These updates are intended to give customers more options for meeting application requirements and improving development workflows.
SLA 825 Dual – The new gold standard in large-frame stereolithography
3D Systems’ new SLA 825 Dual is the Company’s most advanced large-frame SLA printer to date. For customers depending on SLA technology for unmatched surface finish, accuracy, and reliability, the SLA 825 Dual extends that legacy while creating a pathway for continuous performance and throughput improvements. With a new, 20% larger build volume of 830 x 830 x 550 mm, dual-laser architecture, and simplified user workflow, the SLA 825 Dual will continue 3D Systems’ nearly 40-year leadership in high-throughput SLA manufacturing for high performance industries such as transportation and motorsports, and aerospace and defense, as well as service bureaus.
The SLA 825 Dual is engineered for long-term value and scalability—designed to be upgradeable for future technology innovations. 3D Systems will present case studies and technology demonstrations in its booth at Formnext.
The SLA 825 Dual is available for immediate ordering, with the first shipments planned to begin in December 2025.
ArrayCast optimizes foundry workflows, improves efficiencies
3D Systems offers a range of tools for investment casting, including 3D printers, software and build styles intended to help make 3D-printed patterns cost-competitive with traditional wax tooling. For more than 25 years, the company’s QuickCast software has been used by foundries to create lightweight casting patterns directly from CAD models, reducing the need for tooling and supporting design flexibility.
The company has introduced ArrayCast, a software tool that enables users to create casting trees with configurable runners, sprues and end effectors. The digital workflow is designed to streamline tree assembly and reduce manual steps.
Key features include:
- The ability to assemble casting trees digitally before printing, which can shorten production time compared with manual tree-building processes
- Reduced manual labor by allowing printing of fully assembled casting trees, limiting the need for hand gluing or wax welding
- More consistent part production through a digital workflow that reduces variation associated with manual assembly
ArrayCast is available as an add-on within the company’s 3D Sprint software, which supports its polymer printing platforms.
Accura SbF provides dimensional stability for casting metals
3D Systems is introducing another enhancement to its Investment Casting portfolio, Accura SbF. The Company’s latest SLA casting resin has no detectable Antimony, making it the perfect material for printing QuickCast patterns suitable for casting a variety of ferrous and non-ferrous high-performance metals, such as Nickel-based superalloys and Titanium. QuickCastinvestment casting patterns printed with Accura SbF lead to an efficient investment casting workflow with fast print speed, high dimensional stability of the pattern and a high burnout success rate with low residual ash. Accura SbF patterns also have high modulus giving them the ideal rigidity during post processing, pattern assembly and shelling.
The stability of both the low viscosity, fast draining liquid resin and cured patterns is a significant benefit to a cost effective, predictable workflow and casting results. Combined with 3D Systems’ advanced SLA printing technology, including the SLA 825 Dual, and the Company’s 3D Sprint software, Accura SbF quickly creates large, light weight, and easy to handle casting patterns through its industry leading and fully documented QuickCast process.
Accura SbF is available for immediate ordering.
Accura Xtreme Black supports efficient, reliable prototyping
At Formnext 2025, 3D Systems is showcasing Accura Xtreme Black, a high-performance prototyping resin engineered for form, fit, and function applications. It offers exceptional durability for challenging assemblies such as snap-fit components, rugged enclosures, and consumer electronics. Combining Accura Xtreme Black with 3D Systems’ SLA technology can serve as a practical alternative to CNC machining of thermoplastics such as ABS. Its deep black color closely replicates the aesthetics of molded production parts, and the low-viscosity formulation enhances build quality and simplifies finishing, while its sharp detail and dimensional accuracy ensure precise results. With tough mechanical properties and resistance to modest temperatures without distortion, Accura Xtreme Black is the ideal multi-functional resin for SLA.
Accura Xtreme Black is available for immediate ordering.
3D Systems will feature these products in its booth (Hall 11.1, Booth D11) at Formnext 2025 (Nov. 18-21 in Frankfurt, Germany) as part of its full portfolio of solutions for polymer and metal additive manufacturing.
For additional information, visit 3dsystems.com.
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