In the fast-evolving world of additive manufacturing (AM), few challenges are as daunting as producing flight-ready components for military aircraft under the strictest performance and safety standards, a task that demands precision and innovation. At Formnext 2025 in Frankfurt, Wayland Additive, a UK-based innovator headquartered in Huddersfield, has captured global attention by revealing a transformative partnership with the UK Royal Air Force (RAF). This collaboration, showcased at one of the premier events in the AM industry, highlights the real-world application of Wayland’s NeuBeam technology—an Electron Beam Powder Bed Fusion (PBF-EB) process—marking a significant milestone in aerospace manufacturing.
The unveiling at Formnext 2025 not only demonstrates the industrial viability of NeuBeam but also positions it as a trusted solution for high-stakes environments. With a focus on producing critical components for RAF operations, this partnership underscores a shift from experimental technology to proven, reliable innovation. Visitors and industry experts alike are drawn to Wayland’s booth to witness firsthand the impact of this collaboration, setting the stage for a deeper exploration of the event’s highlights and technical breakthroughs.
Event Spotlight: A Historic Partnership at Formnext
Formnext 2025 serves as the perfect platform for Wayland Additive to showcase its groundbreaking work with the RAF, drawing thousands of attendees to Frankfurt for a glimpse into the future of AM. The collaboration, prominently featured at Wayland’s booth (12.0, B139), centers on integrating NeuBeam technology into military applications, a move that signals trust and credibility in the technology’s capabilities. This partnership stands out as a testament to how AM can meet the rigorous demands of aerospace, particularly in producing parts for active service.
Beyond the buzz of the event, the significance of this collaboration lies in its tangible outcomes. A Ti64 titanium component, manufactured using NeuBeam, is now operational on a Typhoon aircraft, representing a major achievement for both Wayland and the RAF. This milestone, celebrated at the event, highlights the transition of NeuBeam from a concept to a solution capable of withstanding the harshest operational conditions, sparking discussions on its broader potential.
The atmosphere at Formnext buzzes with excitement as industry leaders and innovators engage with Wayland’s team to understand the implications of this partnership. Live presentations and interactive displays at the booth offer a comprehensive look at how this technology addresses critical needs in military manufacturing. The event’s focus on real-world applications ensures that attendees leave with a clear sense of NeuBeam’s role in shaping modern AM practices.
Key Moments from Wayland’s Display
NeuBeam in Action: Real-World Success Stories
One of the standout moments at Formnext 2025 comes during a keynote presentation by Wayland’s Head of New Technologies & Founding Member, who shares detailed insights into the RAF collaboration. The spotlight falls on the successful production of a titanium component for a Typhoon aircraft, a part now in active use, proving NeuBeam’s reliability in critical scenarios. This case study resonates with the audience, illustrating the technology’s readiness for industrial adoption.
Peter Hansford, Chief Revenue Officer at Wayland Additive, reinforces this narrative by emphasizing that NeuBeam offers a fail-safe solution for high-stakes applications. His remarks during the presentation highlight the trust placed in this technology by an institution as demanding as the RAF. Attendees note the weight of such endorsements, recognizing the potential for NeuBeam to redefine standards in aerospace manufacturing.
The presentation also touches on the broader implications of this success, suggesting that similar applications could benefit other sectors requiring precision and durability. Discussions following the talk reveal a shared optimism among industry professionals about scaling this technology for diverse uses. This moment at Formnext solidifies NeuBeam’s reputation as more than just an innovation—it’s a proven game-changer.
Technical Edge: Unpacking NeuBeam’s Advantages
Technical discussions at Wayland’s booth dive into what sets NeuBeam apart from traditional PBF-EB processes, with a particular focus on the Active Charge Neutralization (ACN) feature. This innovation eliminates wide-area sintering, a common challenge in electron beam processes, allowing for greater control during manufacturing. Experts at the event explain how this breakthrough translates to enhanced design flexibility and reduced post-processing efforts.
Another point of interest is NeuBeam’s expanded material compatibility, a critical factor for industries like aerospace and energy. The technology’s ability to handle challenging alloys opens new possibilities for producing complex, high-performance parts. Wayland also previews upcoming material datasheets for Inconel 718, signaling ongoing advancements tailored to specific sector needs, which garners significant attention from technical attendees.
These conversations underscore a trend in AM toward greater versatility and efficiency in production processes. Engineers and researchers at Formnext express keen interest in how NeuBeam’s capabilities could address long-standing material limitations. The technical depth of these discussions elevates Wayland’s standing as a leader pushing the boundaries of what’s possible in manufacturing.
Interactive Experiences: Engaging with NeuBeam Up Close
At the heart of Wayland’s booth, visitors engage directly with the technology through live demonstrations of the Calibur3 AM machine, which was first installed at an RAF facility a few years ago. These hands-on sessions showcase how NeuBeam enables rapid, localized production of military-grade components, offering a practical perspective on its operational benefits. The interactive setup draws crowds eager to see the machine in action.
Attendees have the chance to ask questions and explore the nuances of the manufacturing process, gaining a clearer understanding of NeuBeam’s impact on supply chain efficiency. The ability to produce spare parts on demand, as demonstrated, resonates strongly with military and industrial representatives concerned with logistics. This direct engagement fosters a deeper appreciation for the technology’s real-world utility.
The booth’s interactive elements also include visual aids and simulations that break down complex processes into accessible insights. Visitors leave with a tangible sense of how NeuBeam fits into modern manufacturing workflows, bridging the gap between theory and application. Such experiences at Formnext ensure that the technology’s potential is not just discussed but felt by those in attendance.
Exhibits of Innovation: Showcasing NeuBeam-Produced Parts
The physical displays at Wayland’s booth provide concrete evidence of NeuBeam’s versatility, featuring an array of components produced across various materials. Among the most compelling exhibits are parts used in RAF operations, which serve as proof of the technology’s performance under demanding conditions. These displays captivate attendees, offering a visual narrative of innovation in action.
Each showcased item highlights a different aspect of NeuBeam’s capabilities, from intricate geometries to robust material properties suited for extreme environments. Industry professionals scrutinize these components, noting their relevance to ongoing challenges in high-performance manufacturing. The exhibits reinforce the idea that NeuBeam is not a niche solution but a broadly applicable tool for complex production needs.
Complementing the parts on display are detailed explanations of their development process, providing context for their significance. This combination of tangible results and technical backstory creates a compelling case for NeuBeam’s adoption across sectors. The exhibits stand as a highlight of Formnext, embodying the practical impact of Wayland’s advancements in AM.
Reflecting on a Milestone Event
Looking back, Wayland Additive’s showcase at Formnext 2025 marked a defining chapter in the evolution of additive manufacturing, with the RAF collaboration stealing the spotlight. The event demonstrated the power of NeuBeam technology to deliver reliable, flight-ready components for one of the most demanding applications in aerospace. Each presentation, demonstration, and exhibit contributed to a narrative of trust and innovation that resonated with attendees from diverse industries.
Moving forward, the industry must consider how to build on this momentum, exploring ways to integrate technologies like NeuBeam into wider manufacturing ecosystems. Stakeholders should prioritize partnerships that bridge military and commercial applications, fostering shared advancements in material science and process optimization. Additionally, continued investment in research, as seen with Wayland’s work on alloys like Inconel 718, will be crucial to unlocking new possibilities.
The legacy of this event lies in its call to action for AM professionals to push beyond traditional boundaries, leveraging proven solutions to address emerging challenges. As Wayland continues to refine NeuBeam over the coming years, from 2025 onward, the focus should remain on scalability and accessibility to ensure broader adoption. This milestone at Formnext serves as a foundation for future breakthroughs, inspiring a collective drive toward redefining manufacturing excellence.
