3D printing system

At FOOKE GmbH, we combine decades of experience in mechanical engineering with a forward-thinking approach to innovation. As a specialist in portal milling machines and friction stir welding (FSW) systems, we are now taking the next logical step: developing a state-of-the-art 3D printing system designed for the additive manufacturing of large-format components.

Our mission is not just to apply new technologies—but to advance them. The result is a dependable and high-performance 3D printing system based on the proven Additive Friction Stir Deposition (AFSD) process. Unlike many conventional metal additive manufacturing methods, this solid-state process avoids melting the material. The advantages are clear: significantly lower residual stresses, minimal risk of porosity or cracking, and a consistently high level of part quality.

With the AM50, we offer a robust solution for producing large-volume parts with edge lengths exceeding 300 mm. Our customers benefit from FOOKE’s deep expertise, a thoughtfully engineered machine architecture, and a stable process that integrates seamlessly into existing manufacturing environments.

If you’re looking for a 3D printing system built on reliability, precision, and decades of German engineering excellence, FOOKE is the partner you can trust.

No melting - improved rigidity
This print technology does not reach the melting temperature, which keeps the thermal stresses in the component low. In addition, higher mechanical material properties are achieved compared to conventional build-up welding processes.

Wide range of materials
This technology can be applied to a wide range of commercially available metals, including aluminum, titanium, stainless steel and others.

Sustainable, environmentally friendly and resource-saving
By using additive manufacturing, the required components are set up close to the final contour so that the actual amount of material used is minimal. Subsequent post-processing of the components, e.g. by milling, is extremely efficient, as near-net-shape printing requires low machining rates. This also significantly reduces the processing time.

Customization
Customer-specific solutions and individual components are easy to implement using the AFSD process.

Repair
The process is also suitable for repair work (e.g. casting molds). It enables shorter maintenance times compared to the procurement of new parts.

Flexibility of application
With additive manufacturing, there are no limits to the design - even functions that cannot be realised with conventional manufacturing processes can be integrated. Moreover, complete assemblies can be constructed in a single process, e.g. cooling channels or hydraulic lines.

Short production times and flexibility
Complex components can be manufactured directly and no longer require time-consuming procurement times. In addition, customised modifications, e.g. in prototype construction or pre-series, can be implemented quickly and easily.

High deposition rate of up to 14 kg/hour.
due to patented application process.

Material mix
The process enables mixed joints of different materials (e.g. copper and aluminium).

Reduction of milling rates
By producing close contour components, the need for post-processing can be significantly reduced.

Flexibility in the material supply chain
High availability of the printing material.

Automated Process Control: The FOOKE AM 50 features real-time data monitoring, optimized process planning, and advanced fault detection—minimizing downtime and ensuring continuous production.

User-Friendly Interface: The intuitive control software offers a smooth onboarding experience for new users, while providing advanced configuration options for experienced operators.

Safety Features: A fully enclosed system combined with comprehensive safety mechanisms ensures maximum protection for both operators and the machine.

Machine Structure: The machine bed, including the mounted X-axis guideway and portal drive systems, is installed and precisely aligned on the designated foundation. The longitudinal beams, side sections (X-axis), portal (Y-axis), and ram (Z-axis) are all built as rigid steel-welded structures for maximum stability and durability.

Drive Technology – Linear Axes: The X- and Y-axes are driven by rack-and-pinion systems, while the Z-axis is powered by a ball-screw drive. The X-axis features two motors and drives—electronically synchronized on each side to eliminate backlash and gear play between the gear teeth.

Linear Axis Guidance: All linear axes are equipped with preloaded, backlash-free roller guide elements made of hardened and ground components, ensuring high precision and rigidity.

Axis Lubrication: The linear axes feature an automatic centralized lubrication system. Round axes are equipped with a low-maintenance, long-life lubrication system, reducing service requirements and ensuring consistent performance over time.