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Igniting the 3D Printing Revolution

LEAM Technologies Industrializes Additive Manufacturing - a Success Story from the Siemens Research and Innovation Ecosystem Munich

The Unseen Flaw

Imagine constructing a building where each floor rests precariously on the one below it. This analogy perfectly describes what has until now been the fundamental challenge in 3D printing: While liquid plastic was applied layer by layer, the bond between these layers remained a critical weakness. Invisible imperfections at layer interfaces meant conventional methods achieved only 40 to 60 percent of a material's potential strength. This limitation confined 3D printing primarily to prototyping, preventing its widespread adoption in industrial serial production. Munich-based startup LEAM Technologies has now overcome this hurdle with an innovative LED-based technology that finally makes 3D printing viable for industrial applications.

Image of an robot doing 3D printing

From Academia to Industry: The Genesis of LEAM Technologies

LEAM Technologies – an acronym for Light Enabled Additive Manufacturing – wasn't born in a garage, but within the Chair of Carbon Composites at the Technical University of Munich, where a three-person team driven by a desire to transcend purely academic research came together. LEAM CEO Patrick Consul articulates their core insight: "We identified the deficit that 3D printing in companies was largely relegated to development, with only minimal penetration into actual production." Their solution addresses precisely this gap. Based on this clear vision, LEAM Technologies was founded in late 2023 with considerable support by the TUM Venture Lab Additive Manufacturing, which served as a crucial incubator for their company.


DEMEX: The Game-Changing Innovation in 3D Printing

The heart of LEAM's breakthrough is its proprietary Directed Energy Material Extrusion (DEMEX) system. Turning away from mere surface adhesion, DEMEX harnesses the power of high-intensity LEDs. Just before a new layer is deposited, these LEDs precisely heat the underlying printed surface. This process achieves a molecular fusion between layers – a genuine bond that dramatically enhances component strength. "Our technology delivers 3D-printed parts with 100 percent material strength for the first time," says Patrick Consul. "This isn't an incremental step; it's a transformative leap that unlocks entirely new industrial applications."

We use First-Time-Right instead of Trial & Error to propel 3D printing from prototyping to series production.
Patrick Consul, Founder and CEO, LEAM

Agile Startup Meets Industrial Powerhouse

The course to the industrial breakthrough was set by a chance encounter. In August 2022, Markus Obermeier, Business Development Manager at Siemens Digital Industries, met the future LEAM founders – then still doctoral students – at a startup event in the Munich Urban Colab. Obermeier, constantly seeking disruptive technologies, immediately recognized their potential. "At Siemens, we empower 3D printers with our control systems and software. The LEAM solution promised a perfect complement to our 3D printing portfolio, suddenly enabling a host of new use cases," Obermeier explains.
This initial contact blossomed into a deep partnership. Following several collaborative workshops that refined their mutual understanding, a significant milestone was reached in October 2024: At the request of Siemens expert Antonello Pastore, LEAM was integrated into the "Kicks For Edge" funding project. This program allows startups and SMEs to explore Edge Computing without risk. "Kicks For Edge provided LEAM a unique opportunity to grasp our Edge solutions, familiarize themselves with the Edge ecosystem through initial demos and implement their innovation within an OT environment," says Pastore. Fabian Rhein, Strategic Innovation Manager at Munich Urban Colab, adds: "This partnership exemplifies how Siemens proactively supports promising startups, jointly developing solutions for the industry of tomorrow."

Image of an collaboration space in Munich

Intelligent Integration and AI-Powered Quality for Industrial Maturity

The collaboration quickly evolved into a classic win-win scenario. LEAM now leverages Siemens' Industrial Edge platform and precision SINUMERIK controls for its solution. As Patrick Consul wryly notes, reflecting on the startup landscape: "As a startup, people don't always believe we'll be around in three weeks. But with Siemens on board, doors suddenly open." In turn, Siemens is enhancing its 3D printing solution portfolio with an intelligent add-on.
Ultimately, the end customer reaps the benefits: LEAM technology integrates seamlessly with existing Siemens controls and customer hardware infrastructure, eliminating the need for costly new investments, extensive software training and disruption of established workflows. Moreover, LEAM technology makes it possible to process demanding plastics like PEEK (Polyether ether ketone), a previous challenge in large-format 3D printing. An additional advantage is integrated quality assurance: The LEAM system meticulously monitors every print job using infrared cameras, collecting valuable data. This data is then analyzed with AI, ensuring impeccable quality of printed parts – a significant efficiency gain for series production. "This assures customers that every part meets stringent requirements, without the need for time-consuming post-inspections," Consul says.

From Local Ecosystem to the Global Future of Additive Manufacturing

LEAM's success story powerfully illustrates how an innovation-driven environment like the Siemens Research and Innovation Ecosystem Munich can propel ideas to international business success in under three years. Since November 2024, LEAM's technology has been available on the Siemens Xcelerator marketplace. By January 2025, LEAM had secured three new pilot customers from the oil & gas, aerospace, and automotive industries, sectors with exceptionally high demands for material quality and reliability. This development goes beyond mere technical novelty; it is the decisive catalyst that finally propels 3D printing from its prototyping niche into industrial serial production. Alongside partners like LEAM, Siemens is collectively forging the path to establish additive manufacturing as a reliable, high-quality and indispensable production method for Industry 4.0.