EOS who specialise in laser powder bed fusion (LPBF) additive manufacturing (AM), has unveiled the EOS M4 ONYX at Formnext 2025.

“At EOS, our customers have always been at the heart of every innovation,” said Marie Langer, CEO, EOS. “This optimised system was only made possible by the dedication and expertise of our global team. Together, we are shaping the future of metal 3D printing productivity and responsible manufacturing.”

Engineered for Demanding Industries – Designed to meet the needs of energy, defense, space, aviation, and semiconductor sectors, the EOS M4 ONYX delivers:

•             Large build volume: 450 x 450 x 400* mm for larger, more complex parts (*including build platform)

•             High productivity: Six (6) 400W lasers provide 50% higher throughput and reduce part costs by 30%

•             Flexible processing: The EOS M4 ONYX FLX variant features four (4) 1kW beam-shaping lasers for enhanced speed and flexibility

•             Process stability: Homogeneous gas flow and active temperature control ensure cleaner builds and shorter cycles

•             Lower QA costs: Integrated error detection reduces quality assurance expenses by up to 50%

•             Sustainability: More than 90% powder material recovery, lowering raw material costs and waste, supporting Responsible Manufacturing®

•             Cleaner, safter operations: The RFS Pro filtration eliminates consumables and neutralizes hazardous condensate

•             Reliable uptime: Proven technology delivers up to 97% system availability (OEE) with full-service contracts

•             Improved quality: EOS Smart Fusion minimizes supports and enhances surface quality, reducing post-processing

•             Continuous production: Automated overnight starts and job changeovers in under 30 minutes, via the Grenzebach Dual Setup Station – EOS Edition 

Advanced software and processing intelligence: Featuring best-in-class software innovations for efficiency, transparency, and process stability:

•             EOS Build+ process innovations and Siemens control system unlock new productivity levels

•             Open platform communications and web APIs enable seamless integration with digital workflows, reducing order-to-print lead times by up to 30%

•             Early notification systems increase utilization by up to 30%

•             Digital fingerprinting with statistical control cuts QA and non-destructive inspection efforts by up to 50%

•             EOS Smart Fusion and Smart Fusion Replay minimize support and post-processing requirements, and beam-control capabilities double build speeds and expand geometric freedom

Integrated Peripherals & Partnerships – Supported by advanced peripherals and collaborative alliances, transforming it into a fully integrated metal AM production powerhouse:

•             RFS Pro: Enables full powder reuse, eliminates consumables, and reduces hazardous waste by up to 90%, simplifying maintenance and enhancing productivity and sustainability

•             Volkmann Automated Powder Handling – EOS Edition: Delivers closed-loop, scalable powder management for continuous, cost-effective operation

•             Grenzebach Dual Setup Station – EOS Edition: Automates job exchanges in under 30 minutes, enabling true 24/7 productivity

Commercial Availability

The EOS M4 ONYX also features a sleek new design and efficient footprint, and will be commercially available in Q1 2026, with the EOS M4 ONYX FLX variant following in Q3 2026. Materials include titanium, nickel and stainless steel, with additional options available upon request.