BigRep Marks 500th Industrial 3D Printer Delivery: Revolutionizing Large-Format Additive Manufacturing

BigRep, a pioneering leader in the large-format 3D printing sector, recently celebrated a significant milestone: the delivery of its 500th industrial machine. Since its establishment in 2014, the company has rapidly ascended to prominence within the additive manufacturing industry, earning a strong reputation for developing some of the world’s most expansive and capable serial production AM systems. This achievement underscores BigRep’s commitment to advancing industrial-scale 3D printing and its profound impact on diverse manufacturing landscapes. The delivery of this landmark printer signifies not just a commercial success, but a growing validation of large-format additive manufacturing as a critical tool for industrial innovation and production across various sectors.

BigRep’s journey to this milestone has been characterized by strategic collaborations with leading global enterprises, leveraging its technology to develop industrial prototypes, tooling, and high-performance end-use parts. These partnerships highlight the versatility and reliability of BigRep’s solutions in demanding industrial environments. In the highly competitive automotive industry, for instance, giants like Ford and Volvo have integrated BigRep systems into their operations. They utilize these large-format 3D printers for rapid prototyping, creating functional tooling, and exploring innovative applications that accelerate development cycles and reduce manufacturing costs. This adoption by automotive leaders demonstrates the technology’s potential to transform traditional manufacturing processes.

The aerospace sector, known for its stringent requirements and complex componentry, has also embraced BigRep’s capabilities. Companies such as Airbus and Etihad Engineering are deploying BigRep’s advanced 3D printers for a wide array of applications, from producing customized interior parts to developing robust jigs and fixtures. These applications leverage the ability of large-format 3D printing to create intricate designs and lightweight structures, which are crucial for performance and fuel efficiency in aircraft. Beyond these industries, other renowned customers like Bosch Rexroth AG, a global leader in drive and control technologies, and manufacturing firms such as JC Steele & Sons Inc. in the U.S., rely on BigRep for their large-scale additive manufacturing needs. These diverse applications across different industries illustrate the broad applicability and tangible benefits offered by BigRep’s technology. Martin Black, Managing Director at BigRep, succinctly captured the essence of this achievement: “This delivery is more than just a figure, it shows how much industrial customers value our products and the production freedom they create.” This “production freedom” refers to the unprecedented ability to iterate designs rapidly, customize parts, reduce lead times, and produce complex geometries that are often impossible or cost-prohibitive with conventional manufacturing methods. It empowers companies to innovate faster and bring more sophisticated products to market.

The Landmark 500th Machine: BigRep ONE and JAMADE Germany

The esteemed 500th industrial machine delivered was none other than a BigRep ONE. This flagship printer is renowned for its impressive capabilities, boasting a massive build volume of 1005 x 1005 x 1005 mm. This substantial build envelope allows for the production of truly large-scale objects or multiple smaller parts simultaneously, significantly enhancing production efficiency. Furthermore, the BigRep ONE is equipped with two modular extrusion heads, offering flexibility for multi-material printing, support structures, or high-speed dual extrusion, which are critical features for complex industrial applications. The recipient of this milestone machine was JAMADE GERMANY, an innovative e-mobility tech company that recently made headlines with the launch of its groundbreaking underwater scooters, AMAZEA. A remarkable 75% of these advanced scooters are produced using 3D printing technology, underscoring JAMADE’s commitment to leveraging additive manufacturing for cutting-edge product development and production.

Pioneering End-Consumer Product Manufacturing

For JAMADE GERMANY, the investment in an in-house BigRep ONE solution was a strategic decision to streamline the production of these complex 3D-printed parts. By bringing the manufacturing capabilities in-house, JAMADE gains greater control over quality, design iteration, and production timelines, which are vital for a product as innovative as AMAZEA. Detlef Klages, JAMADE’s Managing Partner and Technical Director, elaborated on the significance of this acquisition: “We are very excited about this delivery because it represents a new dimension of industrial AM in end-consumer products, both for us as a company and the industry. The new BigRep ONE will enable us to launch the serial production of AMAZEA as planned, completing our existing fleet of four BigRep ONE printers.” This statement highlights a pivotal shift: large-format additive manufacturing is not only for prototypes or niche industrial tools but is increasingly viable for the serial production of sophisticated end-consumer products. The ability to 3D print such a high percentage of a final product like AMAZEA showcases the technology’s maturity and its potential to disrupt traditional mass production models, offering unprecedented customization, material efficiency, and agility in manufacturing. This move by JAMADE, supported by their expanding fleet of BigRep ONE printers, exemplifies a trend towards distributed, on-demand manufacturing that can respond quickly to market changes and consumer demands.

A Portfolio of Advanced Large-Format Solutions

The BigRep ONE stands as a cornerstone of BigRep’s impressive product lineup, but it is one of several advanced AM systems engineered by the company. BigRep continuously innovates, and its portfolio also includes the recently introduced STUDIO G2 and the BigRep PRO, which represent the company’s next-generation 3D printers, each tailored to specific industrial needs and applications. These machines embody BigRep’s dedication to providing comprehensive solutions for large-format additive manufacturing.

The BigRep ONE: Power and Precision

As discussed, the BigRep ONE is celebrated for its expansive build volume and dual modular extrusion heads, making it ideal for large-scale prototyping, custom tooling, and even direct production of substantial end-use parts. Its open material system and robust construction allow users to experiment with a wide range of filaments, catering to diverse industrial requirements. The machine’s precision and reliability ensure consistent quality even with the largest prints, crucial for demanding automotive, aerospace, and general manufacturing applications where part integrity is paramount.

STUDIO G2 and BigRep PRO: Versatility for Engineering Applications

The BigRep STUDIO G2 offers a slightly more compact, yet still substantial, build volume of 1000 x 500 x 500 mm. Despite its comparatively smaller footprint, the STUDIO G2 is engineered for high performance and specialized applications. It features a fast-heating print bed, which accelerates the printing process and improves adhesion, and a temperature-controlled filament chamber. This controlled environment is critical for successfully printing with advanced and often challenging abrasive and engineering-grade materials such as PETG (Polyethylene Terephthalate Glycol), TPU (Thermoplastic Polyurethane), and PA6 (Nylon 6). PETG is known for its durability and good chemical resistance, making it suitable for functional prototypes and mechanical parts. TPU offers excellent flexibility and abrasion resistance, perfect for seals, gaskets, and impact-resistant components. PA6, or Nylon 6, provides high strength, stiffness, and heat resistance, essential for demanding industrial applications.

The BigRep PRO, on the other hand, combines a very generous build volume of 1020 x 970 x 980 mm with advanced technological features designed for peak industrial performance. Similar to the STUDIO G2, the PRO is optimized to print with the same high-performance engineering-grade materials, ensuring that users can produce robust, functional parts that meet stringent industrial specifications. Both the STUDIO G2 and PRO are equipped with advanced sensors and control systems to ensure precision and repeatability, making them invaluable assets for industries requiring high-fidelity components.

Strategic Material Partnerships with BASF

Recognizing that the true potential of 3D printing is often unlocked by the materials used, BigRep has forged a strategic partnership with BASF, one of the world’s leading chemical companies. This collaboration is designed to provide users with an even broader range of cutting-edge, engineering-grade materials specifically optimized for BigRep’s large-format 3D printers. The partnership allows BigRep customers to fully leverage their machines’ capabilities, pushing the boundaries of what is possible in additive manufacturing. By developing and validating new materials, BigRep and BASF are addressing the diverse needs of industrial applications, ensuring that parts printed on BigRep machines not only offer geometric complexity but also possess the mechanical properties, durability, and performance required for demanding end-use scenarios. This focus on material science is crucial for the continued growth and adoption of industrial large-format 3D printing.

The Transformative Impact of Large-Format 3D Printing

Large-format 3D printing is unequivocally experiencing a significant surge in adoption, with an ever-growing number of innovative applications emerging across a multitude of sectors. This expansion is driven by a confluence of factors, including technological advancements in printer capabilities, material science, and a deeper understanding within industries of how additive manufacturing can solve complex challenges. The ability to print large, intricate components quickly and cost-effectively is proving to be a game-changer for many businesses looking to enhance their manufacturing processes and product development cycles.

NOWLAB: Redefining Design and Manufacturing

At the forefront of this innovation wave is BigRep’s dedicated innovation consultancy, NOWLAB. This specialized division has been instrumental in collaborating with numerous companies, creating groundbreaking designs, and pushing the boundaries of what is achievable with large-format additive manufacturing. NOWLAB acts as a bridge between BigRep’s advanced printing technology and the specific needs of various industries, helping clients conceptualize, design, and realize complex parts that were previously impossible or impractical to manufacture. Their expertise spans various fields, contributing to projects ranging from advanced tooling to intricate architectural models and functional prototypes for electric vehicles, such as the NERA prototype shown previously – a fully 3D printed electric motorcycle that showcases the extreme capabilities of the technology. These collaborative efforts demonstrate how large-format 3D printing can be integrated into existing workflows to foster innovation and generate new revenue streams.

Unlocking New Possibilities and Design Freedom

One of the most compelling advantages of 3D printing, especially at a large scale, is the unprecedented level of design freedom it offers. Unlike traditional subtractive or formative manufacturing methods, additive manufacturing allows for the creation of highly complex geometries, internal structures, and organic shapes without the typical constraints of tooling or molds. This enables engineers and designers to innovate in industries that have historically relied on designs that have remained largely unchanged for decades due to manufacturing limitations. For example, in industrial machinery, parts can be redesigned to be significantly lighter, stronger, or incorporate integrated functionalities that reduce assembly steps. In consumer goods, it paves the way for mass customization and personalized products that cater precisely to individual preferences. The ability to consolidate multiple components into a single printed part, optimize material usage, and produce on-demand prototypes and small-batch production runs contributes to reduced costs, faster time-to-market, and greater agility in a rapidly evolving global economy. BigRep’s commitment to fostering this design freedom through its advanced printers and the expertise of NOWLAB ensures that more industries can leverage these benefits to redefine their product offerings and manufacturing paradigms.

What are your thoughts on BigRep’s large format 3D printing solutions and their impact on industrial manufacturing? We encourage you to share your insights in a comment below or join the discussion on our Facebook and Twitter pages! Don’t miss out on the latest news and innovations in the world of 3D printing – be sure to sign up for our free weekly Newsletter, delivered straight to your inbox!