The merger of ExOne and voxeljet under ExOne Global Holdings marks the end of a historical chapter that traces back to the early days of additive manufacturing. These two companies, which have led the industrial binder jetting field for decades, will once again combine their technological and organizational strengths.
Join Rudolf Franz (former voxeljet, current supervisory board member of ExOne Global Holdings), Dr. Ingo Ederer (co-founder of Sandbinder Jetting), Whitney Haring-Smith (Chairperson of the Board of Directors of ExOne Global Holdings), and Eric Bader (CEO of ExOne Global Holdings) as they reflect on the groundbreaking early days of additive manufacturing, centered around the Technical University of Munich and the Augsburg region.
Where the Journey of Binder Jetting Began
The origins of binder jetting date back to the early 1990s, with initial development taking place at the Massachusetts Institute of Technology (MIT). Around the same time, the Technical University of Munich was also conducting research on binder jetting with the aim of developing an industrially viable additive manufacturing system for foundry applications.
“From the very beginning, it was clear to us that we did not want to develop a laboratory technology,” remembers Dr. Ingo Ederer. “Our ambition was to build a production-ready system that could survive the harsh reality of foundries and deliver real economic value.“
Initial experiments focused on polymer powders. Through discussions with industrial partners such as EOS and ACTech, and with automotive manufacturers such as BMW and Daimler, it became clear that using sand as a material was key to unlocking the true industrial potential of this technology. The decisive factor was the significant productivity advantage of binder jetting compared to existing laser sintering sand methods.
How Sand Is Redefining the Game
“Sand was the game changer,” explains Ederer. “Once we realized that binder jetting could process sand faster, more economically, and at larger scales than alternative technologies, the path toward industrialization became obvious.”
From the outset, the focus was on a solution that could be used immediately in the foundry. Specifically, this involved the right binder chemical composition, high process stability, and scalability to large build volumes. The prescient nature of this approach became apparent around 2000. At the time, an early market survey conducted by a consulting firm estimated global demand at only 11 systems. This reflected skepticism towards this technology, which was far ahead of its time.
Overcoming Technological Hurdles with Persistence
“We were often told that the market simply didn’t exist,” elaborates Rudolf Franz. “But we believed that if the technology truly solved industrial problems, the market would follow—and history has proven that assumption right.”
In its early days, the company faced numerous technical challenges. Various approaches to sand recoating were unstable or difficult to control, while the highly corrosive chemical components placed demanding requirements on materials and machine design. Only through continuous material improvements and the development of new recoating techniques and advanced printhead technologies did they finally break through to a stable and repeatable process. "There were times when success was not guaranteed," Franz admits. "This technology came close to failure many times. What ultimately made the difference was perseverance and the willingness to rethink fundamental steps in the process."
A Game-Changing Moment
In 2003, a patent-related issue led to the original company, Generis, splitting into two strategic paths. voxeljet initially focused on on-demand printing services, later expanding into large-scale systems, while ProMetal (later ExOne) pursued the systematic expansion of its international systems business. Both approaches played a decisive role in the industrialization of 3D sandblasting.
"In retrospect, this split was not a setback, but rather an acceleration," says Ederer. "The two different strategies addressed their respective market needs, and together they propelled binder jetting technology into industrial reality at a much faster pace."
Demands from the foundry industry, particularly the automotive industry, were a driving force behind key innovations. Parameters such as build volume, printing speed, surface quality, system robustness, and material selection were continuously improved in close collaboration with users. The initial system sales to BMW and Daimler in 2002 were a landmark event, and from 2004 onwards, technological breakthroughs continued with the introduction of large-scale facilities in the United States.
"What convinced customers was not a single function, but the reliability of the entire process," Franz points out. "Once automakers began to trust this technology, adoption accelerated rapidly."
By the mid-2010s, printed sand had become the standard technology for prototyping and small-batch production, and from around 2020, multi-system implementations and mass production of complex shapes began to become a reality.
The Driving Forces Behind Binder Jetting
Printheads, the core of binder jetting, have undergone significant technological leaps in recent years. Productivity has increased several times over, lifespan has extended from just a few hours to approximately 4,000 operating hours, and process stability has improved dramatically. Milestones such as the S15 sand printer, PMMA printing, the introduction of SMAX machines, large systems like the VX4000, and recent advancements in automation and productivity have formed the foundation for numerous industrial applications.
"Today, many applications in automotive manufacturing, aerospace, wind energy, or gigacasting would be impossible without 3D sand printing," emphasizes Whitney Haring-Smith. "What started as an experiment has evolved into a core technology in modern foundries."
Larger printers, software-based surface optimization, and further scaling up are generating new momentum. At the same time, CAD design, additive manufacturing design, and structural transformations in the foundry industry remain critical challenges, making expertise and technical knowledge increasingly important.
Leveraging Combined Strengths and Insights
Today, ExOne and voxeljet are once again combining their complementary strengths. With more than 500 systems deployed worldwide, a global network for additive manufacturing is being formed, backed by a robust service infrastructure and integrated development resources.
"Going forward, our customers and partners will benefit from stability and continuity," said Eric Bader, CEO of ExOne Global Holdings. "By combining ExOne's leadership in digital sand casting with voxeljet's expertise in large-scale industrial 3D printing, we are bringing together decades of experience. Our goal is to ensure reliability, drive focused innovation, and achieve sustainable growth."
Therefore, this merger is more than just a strategic step; it symbolizes a consistent new chapter in the history of additive manufacturing, which has evolved from its experimental early stages to a critical industrial technology in the foundry industry.
