AltForm launches ZENIT Modular, large DED cells that can be extended after purchase

Italian maker AltForm will present ZENIT Modular at Formnext 2026, a family of three DED cells for large parts in titanium and aluminium alloys. Customers can add robots and work area after buying, and the company says the first units are already sold to aerospace and defence manufacturers.

Context Directed energy deposition (DED) feeds powder or wire into a melt pool created by a laser or arc, and WAAM is the wire-and-arc variant used for large metal parts.

Three cell sizes, one to four robots

ZENIT L offers a 2 by 2 metre work area with a single robot. ZENIT XL stretches to 4 by 2 metres and carries two robots. ZENIT XXL covers 4 by 4 metres with four robots, which can either share one large component or each build a separate part, up to four at a time.

Robots hang from the ceiling as standard. Floor-mounted robots are offered when a part requires it, and a rotary-tilt table fits either layout.

Inert chamber for reactive alloys

Every cell has an inert chamber, so deposition happens in a controlled atmosphere. AltForm says this allows titanium and aluminium alloys to be processed. Cells can be configured for one process or several: powder DED, wire DED and WAAM. Control runs on a Siemens SINUMERIK ONE CNC.

AltForm, based in Collegno near Turin and part of the Sodick Group, targets aerospace, defence and energy producers with large reactive-alloy components. It says the system can be ordered now and that first units went to leading aerospace and defence companies.

Powder bed fusion systems on the same stand

At Formnext, 17 to 20 November, Hall 12.0, Booth E139, AltForm also shows two laser powder bed fusion machines. The Print Sharp 200 is a single-laser system with a 200 mm diameter, 200 mm high build volume and open parameters, aimed at newcomers, small batches and material qualification. The Print Brilliance 400 has four lasers and a 420 by 420 by 450 mm build volume, prepared for automation. Both share one interface with an AI assistant, remote monitoring, fleet management and blockchain-based traceability.

Other inert-atmosphere large-format systems

3D Printing Industry points to comparable launches: iAM3D's LPW Z2500 laser DED system with a 2000 by 2000 by 2500 mm envelope and argon chamber, and GEFERTEC's arcTitan plasma WAAM machine for titanium, which also uses a SINUMERIK ONE control. All three treat an enclosed inert atmosphere as the baseline for reactive alloys.

What it means

For manufacturers considering large-format DED, the pay-as-you-grow approach lowers the entry commitment, since capacity can follow demand rather than being bought upfront. Still, the reports give no prices, deposition rates or delivery times, so the business case cannot yet be judged. Titanium and aluminium parts for aerospace and defence will also need process qualification and documented material properties, which remain the buyer's effort regardless of cell size. Small and mid sized companies should ask what the extension modules cost and how requalification is handled after an upgrade.

Frequently asked questions

What is ZENIT Modular?

It is a family of three DED cells from AltForm with inert chambers for titanium and aluminium alloys, supporting powder DED, wire DED and WAAM. Work area and robot count differ by model.

Can the system be expanded after purchase?

Yes. AltForm says modules can be added later, so a manufacturer can start with the size it needs and extend work area and robot count as demand grows.

Where can ZENIT Modular be seen?

At Formnext 2026 in Frankfurt, 17 to 20 November, in Hall 12.0, Booth E139, together with AltForm's two powder bed fusion machines.