Schaeffler Omni Family – a cross-industry revolution in manufacturing
3 dimensional multi-material printing allows up to three different materials to be used in a single printing process. This enables the production of versatile products that would otherwise be difficult to achieve using traditional methods. For example, components with solid cores, flexible outer layers, and conductive elements can be produced in one step. This simplifies the production process, eliminates the need for multiple steps and allows for the design of advanced, efficient and functional components. Therefore, 3D multi-material additive manufacturing has the potential to transform product development, manufacturing and usage.
Development of revolutionary machine systems through the merger of a global player and a start-up - the shift to multi-material 3D printing
The field of 3D printing is developing rapidly, opening fascinating new possibilities that go beyond traditional monomateri-al printing. Although monomaterial printing was the starting point for additive manufacturing and has already led to sig-nificant advances in design flexibility and production speed, the future will be defined using various materials that can fulfil specific functional requirements.
Innovation meets decades of experience in manufacturing solutions
There the merger of Schaeffler Special Machinery and Schaeffler Aerosint marks a turning point in additive manufacturing that sets new standards. We are addressing the additive manufacturing market by combining expertise in groundbreaking multi-material 3D printing technology and more than 70 years of experience in realizing production solutions for industrialization and automation of processes. Our machine solutions will unlock completely new possibilities for production workflows and freedom in product design. Complex geometries, customized designs, and functional material combinations - all in a single printing process. Together, we are accelerating innovation processes and responding more quickly to market requirements.
OmniFusion 3D – System for multi-material additive manufacturing
Our OmniFusion 3D is a revolutionary manufacturing system for L-PBF technology, including our so called recoater system and up to four laser sources. The advanced Recoater is at the heart of the process of handling multiple materials during the printing process. It ensures an even distribution of powders with pixel-precise accuracy in each layer, significantly improving the quality and uniformity of finished surfaces. Up to four laser sources permit precise control when processing materials, enabling different materials to be processed simultaneously with different wavelengths and intensities. This versatility allows complex components with specific properties to be produced in a single pass. Combining these technologies optimises production speed, minimises material waste, and opens up new dimensions in additive manufacturing that were previously unattainable. The Schaeffler OmniFusion 3D therefore sets new standards in the manufacturing industry by offering tailor-made solutions for demanding industrial applications.
OmniForm 3D - Additive powder structuring for classic thermal processing
Our form-filling platform, the OmniForm 3D may be former known as Die Filling Platform or DFP. The system enables powders to be placed precisely in a mould with an inner diameter of up to 100 mm / 4 inches. Same as for the OmniFusion 3D once again the Recoater ist the core element for realizing the powder layers in combination of the defined materials.The placement of the powder is determined based on a digital design defined by the user. Once transferred to the machine's control software, the mould is filled automatically, layer by layer, and can then be sintered using conventional or pressure-assisted methods.
Metal & ceramics – at the core of our development work
A notable trend in advanced manufacturing is the printing of different metals, which enables the production of compo-nents with customized conductivity. This capability is particularly valuable for electronic systems, where integrating metals with variable conductivity can significantly enhance the efficiency and functionality of electrical circuits.
Beyond electronics, the combination of metals and ceramics opens up new possibilities for precise thermal management in individual components. Hybrid structures that integrate ceramics into metal frameworks allow for controlled thermal con-ductivity while maintaining mechanical stability. These properties make such components ideal for high-temperature appli-cations, especially in demanding industries like aerospace and automotive.
By merging the unique advantages of metals and ceramics, we are shaping the future of multifunctional components that meet both electrical and thermal performance requirements.
Next Steps – outlook for additive manufacturing
One of the most exciting developments is the ability to print complex parts, such as electric motor blocks, in a single pass using various material combinations. This technique allows functional elements to be integrated directly into the structure, reducing the need for assembly steps and significantly increasing manufacturing efficiency and reliability. Such advanced applications mean entire assemblies with different mechanical, electrical and thermal properties can be produced directly by the printer.
Overall, the outlook for 3D printing shows a clear trend towards multi-material solutions that will transform the way we manufacture and design. These technologies offer new functions and increased efficiency, as well as the opportunity to make production processes more sustainable and resource-efficient.
August 2025