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3D Printing Reinvents the Bass Drum Without Missing a Beat

BigRep 3D printed drum cover image

What possesses someone to reinvent a musical instrument that’s been around for thousands of years?  

Oliver Deeg, a product engineer, and musician will tell you: boredom, curiosity, and a firmly rooted knowledge of additive technology. His dream? To create drums that aren't confined by traditional manufacturing limitations. His tool of choice? Large-format 3D printing.

https://www.youtube.com/watch?v=XWWZEfa-Y00

Defying Conventional Constraints

Oliver Deeg is a man of talents and passions; CAD design, additive 3D printing technology, and e-commerce being the mainstays. His vision is to push the boundaries of design and music through Additive Manufacturing. 

Like most drummers, customizing and building his own drum kit has always been his dream. His journey began alongside a friend crafting drum sets in wood, but the constraints of traditional methods held him back from making the design truly his own. 

BigRep 3D printed drum Oliver Deeg

Meticulous woodworking is the time-tested way of crafting a bass drum. It begins with selecting quality wood like maple or birch, dried to prevent warping. Wooden staves are shaped and glued together to form a cylinder, creating the drum's shell. Precise bearing edges are then cut to optimize contact between the drumhead and shell, crucial for tone. The holes are then drilled for hardware, and the shell undergoes thorough sanding and finishing. Drumheads, made of synthetic or animal skin, are attached using tension rods. Finally, the hardware is assembled, and fine-tuning adjusts the drum's tension rods for the desired pitch and resonance. This intricate process demands skilled craftsmanship and attention to detail to create a bass drum. 

This process has been stagnant and leaves little room for experimenting with sound and design. Oliver saw the potential to produce drums that would be free of these limitations. He turned to 3D printing and his expertise in Additive Manufacturing proved advantageous, with which he began producing small drums. From small prototypes, his ideas snowballed into more ambitious projects. True to the heart of a musician and the mind of an engineer, he couldn’t help thinking BIGger.

BigRep 3D printed drum

"With 3D printing, it was the first time that I felt there are no real borders. You conceptualize an idea, and within hours, you hold a tangible prototype. It's such a dream come true”

Dreaming BIG

The turning point came when Oliver crossed paths with BigRep at Formnext 2022 which led to a collaboration that propelled his vision forward. BigRep's range of materials and large-format 3D printers were instrumental in materializing his vision - A 24 Inch Base Drum with 6 USPs: 

  1. Cone-shaped inner shell to explore new unique sounds. 
  2. Relief shell design for stability and an aesthetic finish. 
  3. Sound + cable hole to release air pressure and also double up as a means to insert microphones into the drum. 
  4. Hollow-shaped fill hole to hold granulates such as sand or can also contain water. When empty, it produces more of a violin-like sound, and when filled, results in lower frequencies. 
  5. Customized hoops to hold the drumhead. 
  6. Experimentation with a range of materials to find the best sound, fit, and finish.
BigRep 3D printed drum with lugs

He adds,

"The collaboration with BigRep was a game-changer. Their advanced printing capabilities enabled the creation of drums with exceptional quality."

Anatomy of the 3D Printed 24-inch Bass Drum

3d printed bass drum

  1. Relief Shell Design For stability and an aesthetic finish. 
  2. Holes for lugs Space for metal lugs to hold the tuning screws. 
  3. Cone Shaped Inner Shell Crafted like a megaphone, it is instrumental in creating new sounds. 
  4. The Drum Shell Main body of the drum. 
  5. Screw Holes To secure lugs from the inside. 
  6. Sound and Cable Hole Releases air pressure and doubles as a space to insert microphones inside the drum. 
  7. Hollow Shell with Fill-Hole for granulates such as sand or can also hold water.  
  8. Hoops to hold the drumhead crafted for the 3D-printed shell. Produced twice.  

Oliver's drum set is an embodiment of unconventional acoustic principles. Inspired by how sound amplifies in conical shapes, his design incorporates two shells with an acoustic space between them—a feat unattainable through conventional methods. 

He elaborates,

"Finding the right material and producing a large-scale print of this size was the biggest challenge. The drum took a few days to print. The surface, straight from the printer, was immaculate, there was no need for post-processing."

BigRep 3D printed drum close-up

3D Printing Hits the Right Note 

Plastic drums are nothing new, they’ve been around for a while. But they all have a distinct sound and feel that doesn’t stand out the way that the 3D-printed bass drum does. The very first impression of the drum for Oliver was that it sounded incredible. Not only did the sound and design deliver, but also the material and construction of the drum held its ground. When he put it under the microphone in the studio, the real difference showed up. It did not just compete with a regular drum but also sounded distinct because of its USP – The Conical Inner Shell. 

BigRep 3D printed drum Oliver Deeg in a recording studio

Starting out, Oliver knew designing the 3D file, pushing print, and producing the drum parts wasn’t going to be a simple ride. What is usually perceived as easy geometry is not, and the drum required expertise and accuracy that, along with BigRep, he was able to achieve making him a firm believer that the next wave of drum customization belongs to Additive Manufacturing.  

Given his fascination with 3D printing technology, it’s no surprise that he sees it as not just being a catalyst for a new era in creating musical instruments but also integrating into our everyday lives. For him, the future holds a fascinating prospect—a world where every household could house a 3D printer, becoming an answer for personalized on-demand production. 

“I envision a day when a 3D printer sits in every home, where ordering something means it materializes straight out of your own printer,"

Oliver concludes.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

The Definitive Guide to 3D Printing: The Past, Present, and Future

BigRep ONE.4 Large-Format 3D Printer

From its humble beginnings as a niche technology for rapid prototyping to its current spectrum of capabilities to create forms that are virtually impossible to build any other way, 3D printing has spawned a brand-new generation of manufacturing.

In this article, we’ll take a look at the origins of 3D printing, its big moments in history, applications, and explore the future it holds.

Table of Contents

1. The Basics of 3D Printing

What Is 3D Printing and How It Works

3D printing, also known as additive manufacturing, is a process of building a physical object from a three-dimensional digital model. It creates an object by laying down successive thin layers of a material such as plastic, metal, resin, or even biomaterials—based on a digital design created using computer-aided design (CAD) software.

3D Print Speed

The process begins with the digital 3D model sliced into numerous thin layers. The 3D printer then follows these instructions, precisely depositing material layer upon layer, gradually constructing the physical object. This technology has found applications across a gamut of industries, including aerospace, healthcare, automotive, fashion, architecture, and more.

Types of 3D Printing Materials

3D printing materials can be categorized under:

  1. Plastics (PLA, ABS, PETG, nylon)
  2. Metals (stainless steel, titanium, aluminum, copper)
  3. Resins (standard, flexible, tough, castable)
  4. Ceramics (porcelain, stoneware, earthenware)
  5. Wood pulp with a binding polymer (Bamboo, Birch, Maple, Cherry)
  6. Composites (carbon fiber, fiberglass)
  7. Paper-based (cardboard and paper)
  8. Food-based (chocolate, dough, sugar)
  9. Bio-based (living cells and tissue)

The History

Evolution and history of 3D printing

The roots of 3D printing go back to the 1980s when visionaries like Hideo Kodama proposed methods for fabricating three-dimensional models using photopolymers solidified by UV light. Around the same time, Charles Hull pioneered stereolithography, patenting the concept in 1986. This technique employed UV light to solidify layers of liquid photopolymer resin, laying the groundwork for additive manufacturing. Subsequent decades saw the evolution of various printing methods like Selective Laser Sintering (SLS) and Fused Filament Fabrication (FFF), expanding material options and applications.

By the 2010s, 3D printing had become more accessible, integrating into industries such as aerospace, healthcare, and automotive manufacturing. Bioprinting also made strides, enabling the printing of living tissues and organs. Today, 3D printing stands as a transformative force, reshaping manufacturing, rapid prototyping, and medical advancements through its capability to produce intricate designs with precision and speed.

The advantages

Benefits of 3d printing Across Industries

Rapid Prototyping

3D printing enables quick and cost-effective prototyping, allowing designers and engineers to iterate designs swiftly, reducing time-to-market for new products.

Highly individualized products can easily be produced catering to specific needs and preferences without significantly increasing production costs.

Customization

Complex Geometry

Unlike traditional manufacturing methods, 3D printing can create intricate geometries and complex designs that would be challenging or impossible to achieve otherwise.

Additive manufacturing is inherently more efficient, as it typically uses only the materials necessary for the object being printed, minimizing waste.

Reduced Material Waste

Supply Chain Efficiency

On-demand production enabled by 3D printing reduces the need for large inventories and streamlines the supply chain by producing parts as needed.

For small batches or low-volume production, 3D printing can be more cost-effective than traditional manufacturing methods due to lower setup costs.

Cost-Effectiveness

Innovation in Medicine

Creating patient-specific implants, prosthetics, and medical models for surgical planning requires precision and customization which 3D printing delivers effortlessly.

3D printing has become an invaluable tool allowing students and researchers to visualize concepts and create prototypes to test theories in various fields.

Education and Research

2. Common Types of 3D Printing Technologies

BigRep One - Amir & Bea

Fused Filament Fabrication (FFF)

FFF is one of the most common 3D printing methods. It works by melting a thermoplastic filament and depositing it layer by layer through a heated nozzle onto a build platform. As each layer cools, it solidifies, gradually building the object. FFF is known for its simplicity, affordability, and versatility, making it popular for hobbyists and prototyping.

Stereolithography (SLA)

SLA employs a vat of liquid photopolymer resin and uses a UV laser to solidify the resin layer by layer, building the object from the bottom up. The UV laser traces the shape of each layer onto the surface of the liquid resin, solidifying it. SLA is known for producing high-resolution, detailed prints, making it suitable for applications requiring precision, such as dental and medical prototypes.

SELECTIVE LASER SINTERING (SLS)

SLS uses a high-powered laser to selectively fuse powdered material, typically nylon or other polymers, into a solid structure layer by layer. Unlike SLA or FFF, SLS doesn't require support structures as the unsintered powder acts as a support. SLS offers design flexibility and can produce complex geometries and functional prototypes with robust strength, making it common in the aerospace and automotive industries.

POLYJET PRINTING

PolyJet technology operates similarly to inkjet printing but with layers of liquid photopolymer cured by UV light. Tiny droplets of liquid photopolymer are instantly cured by UV light, solidifying it, layer by layer, onto a build tray. PolyJet printers can produce multicolor, multi-material parts with high accuracy and fine details. It's often used in industries requiring high-resolution models, such as product design and architectural prototyping.

3. Real-World Applications Across Industries

Advancing-Additive-Manufacturing-in-Aerospace_Hero

1. Aerospace and Defense

Lightweight yet durable components are the lifeblood of the aerospace and defense industry. Components like turbine blades, fuel nozzles, brackets, and even entire rocket engines can be 3D printed. This results in reduced component weight, improved fuel efficiency, and enables rapid prototyping for testing different designs.

2. Automotive

In the automotive industry, 3D printing is used for rapid prototyping, and creating functional prototypes for testing and validation before mass production. Additionally, it's utilized for manufacturing parts like engine components, interior elements, custom tooling, and even entire vehicle bodies. The technology allows for quicker design iterations and the production of complex parts, enhancing overall efficiency in the automotive manufacturing process.

Car Restoration: 3D Printed Center Console
FDM vs SLS Healthcare: 3D Printed Wheelchair

3. Medical and Dental

3D printing has transformed the medical and dental fields by enabling the production of patient-specific implants, prosthetics, and surgical tools. In dentistry, it's used to create crowns, bridges, and dental models tailored to individual patient needs. In medicine, it's utilized for creating anatomical models for surgical planning, prosthetic limbs, customized orthopedic implants, and even bioprinting tissues and organs for transplantation and research purposes. These offerings deliver personalized solutions and improve patient outcomes.

4.  Consumer goods

Embraced by leading companies across sectors like consumer electronics and sportswear, 3D printing has democratized manufacturing processes with the accessibility of industrial 3D printers. This accessibility empowers designers and engineers to delve into its immense potential. Its benefits include expediting product development through rapid prototyping, accelerating time-to-market, and enabling mass customization by efficiently catering to individual consumer preferences.

BigRep ONE 3D-Druck-Service
3D Printed Jigs and Fixtures Ebook

5. Industrial Applications

The industrial goods sector, pivotal in machinery and equipment production, grapples with the need for agility and cost-effectiveness amid escalating costs and digital advancements. To address these challenges, manufacturers turn to 3D printing for its agility, responsiveness, and innovation. Its advantages lie in rapid prototyping, on-demand production, slashing design change times, and cutting lead times by eliminating tooling requirements.

4. Seven Steps to Find the Right 3D Printer

Building on the foundation of 3D printing basics, types, and applications, you can now quickly narrow down the vast choice of 3D printers by considering factors like:

1. Type of Printer

Consider various technologies such as FFF (also called FDM), SLA, and SLS. Inexpensive desktop FFF printers may suit hobbyists, while SLA and SLS offer higher accuracy at a higher cost.

2. Cost of the Printer

Entry-level printers cost less than $500, while industrial-grade printers can go up to hundreds of thousands of dollars. Also, factor in maintenance and filament costs.

3. Printer Size and Volume

Evaluate available space and print size needs. Beginners may opt for smaller, faster printers while for industries it’s recommended to invest in large-format 3D printers.

4. Print Quality and Speed

Take resolution, layer height, and print speed into consideration. Higher resolution often means slower speed and vice versa.

5. Ease of Use

Look for user-friendly interfaces, easy calibration, automation, and reliable performance. Consider reviews for insights into reliability.

6. Support and Maintenance

Check for maintenance instructions, available replacement parts, and technical support. Some companies offer less expensive, build-your-own 3D printers while others offer a full-service package. Also look for community support as it can be a holy grail in troubleshooting your 3D printer.

7. Additional Features

Consider extras like multiple extruders for varied prints, auto-calibration, built-in cameras, touchscreen displays, proprietary 3D software, and internet connectivity based on personal needs and budget considerations.

5. The Future Of 3D Printing

BigRep PRO on MARS

3D printing holds vast unexplored potential to reshape our everyday lives by offering innovation, customization, sustainability, and efficiency through:

  1. Diverse Use of Material
    Expect a widening array of printable materials, including advanced polymers, metals, ceramics, and bio-compatible substances, expanding the scope of applications.
  2. Accessibility
    As technology progresses, 3D printing might become more accessible, affordable, and user-friendly, potentially integrating into everyday homes and workplaces.
  3. Sustainable Manufacturing
    Efforts towards eco-friendly printing using recyclable materials and reducing waste during the printing process are gaining traction, contributing to sustainable manufacturing practices.
  4. Bioprinting and Healthcare
    Advancements in bioprinting may revolutionize healthcare by facilitating the creation of tissues, organs, and medical implants, leading to personalized healthcare solutions.
  5. Integration with AI and Robotics
    The fusion of 3D printing with AI and robotics could streamline and automate the entire printing process, enhancing efficiency and precision.
  6. Space Exploration
    3D printing's potential for on-site construction using locally available materials might revolutionize space missions and support off-world colonization.

Past production advancements were typically gradual, building upon iterations by refining production lines and inventory systems. In contrast, 3D printing reimagines production at a fundamental level. It simplifies, accelerates, and streamlines the creation process using a single machine, deviating from the reliance on a string of machines.

This paradigm shift is why most industries invest in this technology, firmly believing in the promise 3D printing holds in exploring untapped industrial applications in the manufacturing sector. From the invention of the telephone to the personal computer, there have been milestones in human history when a technology has completely transformed society. Now is one of those times.

Want to learn more about Large-format Additive Manufacturing?

Download the eBook Guide to Integrate Large-Format Additive Manufacturing.

Explore how increasing the build size increases the possibilities for builds, why size matters, how to integrate, 4 applications that benefit from large-format additive, case studies from industry-leading companies like Ford, Steel Case, and more.

GUIDE TO INTEGRATE LARGE-FORMAT ADDITIVE MANUFACTURING

INDUSTRIAL QUALITY MEETS  COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

BigRep Turns Up The Heat With HAGE3D Acquisition

Reinhard Festag (Managing Director, BigRep), Matthias Katschnig (CTO, HAGE3D), Sven Thate (Managing Director, BigRep), and Thomas Janics (CEO, HAGE3D) at Formnext 2023.

In our quest to offer exceptional Additive Manufacturing technology, solutions and expand our capabilities, today marks a monumental day in the history of BigRep as we announce the acquisition of HAGE3D. This partnership signals a giant leap toward our vision of becoming a full-solution ecosystem for a range of low to high-temperature applications, offering a powerhouse of innovation and possibilities. 

The collaborative path with HAGE3D will unlock new opportunities in the industrial 3D printing landscape. Together, we offer a comprehensive portfolio of industrial 3D printers, featuring up to one cubic meter build volume and the capabilities of a wide range of high-performance, engineering-grade thermoplastic materials in low, mid, and high-temperature build chambers.

Redrawing the AM Landscape

HAGE3D, renowned for its high-temperature 3D printers and open AM platform, will empower BigRep to offer a full spectrum of low-to-high-temperature solutions. The acquisition is built on a foundation of extensive technological synergies, data-driven innovation, exceptional customer experiences, and an ambitious expansion plan, further strengthening BigRep's position in the industry and extending our market reach.

The Collabosphere, a 3D printed demonstration of the joined forces of BigRep and HAGE3D with a wide range of materials from both companies, seen here at Formnext 2023.
The Collabosphere, a 3D printed demonstration of the joined forces of BigRep and HAGE3D with a wide range of materials from both companies, seen here at Formnext 2023.

The Acquisition Disrupts Existing Possibilities

Both companies are committed to the development of intelligent FFF technology, making the production of complex, large-format functional parts accessible to manufacturers worldwide.

Dr.‐Ing. Sven Thate, Managing Director of BigRep GmbH, expressed his excitement about the merger, highlighting how it positions BigRep as the AM market continues to grow dynamically. The 3D printing world is driven by megatrends such as digitization and decentralization of manufacturing and BigRep, with the addition of HAGE3D, is well-prepared to capture this opportunity.

Dr.‐Ing. Sven Thate, Managing Director of BigRep GmbH, elaborated:

“For our worldwide customers, this acquisition makes us their local provider of open industrial AM solutions across all temperature levels, unlocking limitless material options. Together, with similar mindsets of customer-centric, data-driven innovation, we plan to form a European leader pushing the limits of what is possible with FFF.”

BigRep PRO and BigRep SHIELD
The BigRep PRO and the BigRep SHIELD
The HAGE3D MEX ONE
The HAGE3D MEX ONE

Thomas Janics, Managing Director of HAGE3D, emphasized the global growth opportunities enabled by HAGE3D's high-temperature FFF platforms expanding BigRep's material portfolio and large-format AM solutions. Complementing its current low‐temperature and energy‐conscious large format AM platforms, this will open a broad spectrum of new applications and markets.

Thomas Janics, Managing Director of HAGE3D, explained:

“With BigRep we have found a perfect partner to accelerate the attractive global growth opportunities in the industrial AM sector. While our focus was previously on the German‐speaking markets, we now can provide our products globally through BigRep´s sales network, adding Graz to the map of technology centers next to BigRep’s in Berlin, Boston, Shanghai, and Singapore. It’s a win‐win in R&D, production, and sales. Therefore, we jointly look forward to an innovative, unique, and successful future together.”

Collabosphere and team at formnext 2023

Joining Forces for Innovation

With more than 1,000 large-scale 3D printers already in operation across various industrial sectors, BigRep has earned its reputation with its expertise in large-scale Fused Filament Fabrication (FFF). The German-engineered 3D printers empower engineers, designers, and manufacturers, spanning from startups to Fortune 100 corporations, to expedite the transition from prototyping to production, ensuring their products reach the market promptly.

On the other hand, HAGE3D is an advanced engineering company with 40 years of experience in large-format, special-purpose machine building. Their state-of-the-art large-format mid- and high-temperature 3D printing systems are known for their precision and reliability. Fully assembled in Austria using industrial-quality components, these machines perform consistently across a wide range of industries and applications.

By forming an alliance with HAGE3D, BigRep is poised to expedite innovation and redefine manufacturing practices. This integration is underpinned by a fully integrated open AM business model, promising to offer users a replete solution.

As BigRep and HAGE3D come together, we will continue to push the limits of what is possible with FFF technology, accessing a world of opportunities in large-format, open additive manufacturing.

Find out more at https://bigrep.com/press-media/

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

AM in Low Volume Production: High Speed, Quality, And Cost Efficiencies

While developing a new product, the leap from design to production is one of the biggest hurdles to overcome. And with low volume production of 100-1000 parts, the cost and time sink of getting to market are multiplied exponentially and might be prohibitive.

In recent years, there’s been a growing focus on additive manufacturing as not just a prototyping technology but a full-fledged tool for low volume production, customization, and mass customization. Embracing large-format additive manufacturing for small-scale production has created a paradigm shift in fostering innovation, streamlining operations, and delivering significant cost reductions through cutting-edge 3D technology.

Ultimately, the crux of leveraging 3D printing is contributing to a single bottom line – operational efficiency.

What is Low Volume Production?

Also known as low-volume manufacturing (LVM), is as the name implies - the production of parts on a smaller scale. Low volume production lies halfway between prototyping and mass production. This offers manufacturers a space where they can blend the flexibility of the former with the precision and repeatability of the latter.

Production of precise tooling, functional prototypes, custom parts, jigs and fixtures, and spare parts in limited quantities are some examples of low volume production scenarios. LVM is particularly advantageous when it comes down to cost-efficiency, customization capabilities, and rapid prototyping while gaining faster market access.

Big 3D Print Batch Printing

What Drives the Demand for Low Volume Production?

Small quantities of parts needed for:

1. Customization

The growing demand for personalized products and components has surged low volume manufacturing. Customization production relies on an automated, efficient, and lean supply chain set-up that requires a great deal of flexibility making 3D printing an ideal fit.

Low volume production also encompasses mass customization as businesses need variations of concepts to realize which features can be customized, and how to best implement them in their product lines.

2. Niche Markets

Many industries require short production runs with specific requirements for niche markets. Low-volume 3D printing is well-suited for these scenarios, as it enables the cost-effective production of limited quantities of specialized products that would otherwise be hard to serve. This includes specialty vehicles, one-off products, or nonstandard designs.

3. R&D and Innovation

Low-volume manufacturing helps in making real strides by responding to market demand and introducing new features and products at a faster pace. It enables rapid prototyping and production of units for testing, validating, and refining new designs and components. This capacity for rapid innovation is crucial in creating groundbreaking ideas by introducing new products and technologies ahead of competitors.

omni-platform-web

4. Sustainability

As environmental concerns grow, low-volume manufacturing reinforced by 3D printing underlines efforts for sustainable production methods. 3D printing's additive nature, which builds up material layer by layer, reduces material waste and energy consumption compared to traditional subtractive manufacturing methods. By producing only what is needed and minimizing waste, it aligns with sustainable manufacturing practices.

Low Volume Production Scenarios

1. Tooling

It’s hard to overstate the impact of tooling in the production process, especially in the automotive industry. With traditional methods, tooling lead times can take months and costs run high.

By incorporating additive manufacturing, the production of tools like molds, jigs, assembly, and inspection fixtures is economical and time-effective resulting in shorter lead times. Thereby expediting design and raw materials validation before transitioning to production.

low-volume-production tooling
Canyon_inspection

2. Rapid Prototyping

It’s a given that initial designs are prone to imperfections, so prototyping allows engineering to try out parts and explore possibilities. The ability to swiftly implement changes is advantageous in such scenarios as low volume production offers the flexibility for making real-time adjustments.

Originally 3D printing was developed for rapid prototyping, so it’s no surprise that it’s a natural choice for low volume production processes.

3. Temporary Parts

When manufacturers need a part for a machine or a prototype, it might take a while for the replacement to arrive, leading them to seek out alternative methods to avoid delays.

Low volume production encourages uptime by being a stand-in until the ordered part comes through. With an in-house 3D printer, the part can be produced with materials like BigRep’s TPU that’s flexible yet strong. 

Ford jigs and fixtures low volume production
Audi Breathe Chair 3D print on BigRep ONE

4. Bridge Production

Low volume runs of a part might be required between the interim stage of product development and full-scale production. These units are samples for testing, fit checks, verifying the design, checking conformance quality, and eliminating foreseeable defects.

This is vital for newly developed products or components to avoid any risks before mass production.

5. Small-Quantity Production

Low or sporadic demand, initial pilots of a new product or market, parts produced in limited editions, and specialized components raise the need for small-quantity production.

Reliance on outsourcing production might not be the most cost and time-effective as typically there’s a minimum order quantity and no flexibility in changing the order size. Also, the limited window to make iterations to products before hitting the market encourages manufacturers to create in-house low volume production workflows.

BigRep-Application-Batch_4
BigRep ONE.4 Large-Format 3D Printer

6. Produce on Demand

When there isn’t predictable demand, the production of units as and when needed helps with avoiding the high costs. This just-in-time manufacturing approach in low quantities is an alternative to maintaining inventory management in warehouses.

Parts can be 3D printed on-demand, eliminating logistical challenges, minimizing the risk of overstocking, and reducing the time it takes to fulfill and respond to changing requirements.

7. Fabrication of Obsolete or Discontinued Parts

In some cases, especially with legacy systems or machines, certain components may become obsolete or discontinued. Low volume 3D printing can provide a cost-effective solution by reverse engineering and fabricating replacement parts, extending the life of equipment that might otherwise be rendered unusable.

LVM is particularly valuable in building a spare inventory of replacement components where production volumes are low.

Airbus

Why 3D Printing is the Answer

1. Growing Acceptance and Versatility

Factors like design freedom, reliable quality prints, prototyping capabilities, repeatability, low cost, and a hands-off approach have created a surge in the adoption of LVM 3D printing. Industries are taking the printing process into their own hands, ensuring their products are leading the market in innovation by introducing new designs and features before competitors.

BigRep PRO 3D Printer

Also when it comes to the range of materials, 3D printers such as the BigRep PRO have a diverse engineering-grade filament portfolio and are open to third-party materials enabling flexible applications.

2. Automated for Peace of Mind

Automation enables lights-out manufacturing minimizing the dependence on highly skilled workers, furthering peace of mind in the production process.

Safi Barqawi, the owner of AVI Boston, an Automotive Custom Fabrication company talks about about how the BigRep Studio is like an extra pair of hands in his workshop.

"Finding skilled fabricators and installers are a challenge, but with our 3D printer, it's like having a full-time employee building parts. We design, press print, go away for the weekend and all the parts are ready by Monday morning."

BigRep Fiber-Ready PEX (Power Extruders)

3D printing software such as BigRep’s, aids material handling, remote print monitoring, data analytics, auto calibration, batch production, automated design, and workflows. This results in closer ties and predictable workflow timelines across the length of the print process. The best part of using these softwares is that it requires no prior experience in 3D printing or CAD software skills reducing the learning curve for operators.

3. Excellent Part Accuracy and Build Volume

3D printing technology excels in ensuring the accurate production of large to small sized parts, a critical aspect in maintaining product quality. The exceptional tolerances ensure the creation of complex geometries with precision, making it a reliable choice for manufacturing high-quality, sizable parts.

“The biggest advantage of large-scale 3D printing is getting rid of assemblies. When we can produce bigger parts in one piece, this gives us a huge advantage.”

Lars Bognar, a research engineer for additive manufacturing at Ford Engineering Europe.

BigRep-One-printing

The large build volume enables the efficient batch production of multiple parts or larger components in one go. This reduces the need for assembly, streamlines the manufacturing process, and is cost-effective.

4. Low-Risk Investment, Offering Time and Cost Savings

Unlike traditional methods that involve cutting parts from large chunks of non-recyclable materials, 3D printing uses only uses what’s required, drastically reducing waste and material costs. This resource-efficient approach aligns with sustainability goals while simultaneously offering financial savings. The option of printing parts as needed also brings down costs associated with inventory and logistics.

WAT Berlin, an automotive manufacturer specializing in the production of vehicle frames is dramatically improving workflows in their facilities with custom 3D printed parts. André Lenz, an engineer at the Berlin facility elaborates on how the BigRep ONE has been enabling the production of light-weight, durable components.

“If we had made them out of steel or aluminum, for example, it would have been incredibly expensive and above all heavy and made from multiple parts.”

3D printing simplifies manufacturing by serving as a one-step process, eliminating the need for multiple machines, thus saving valuable time and reducing associated costs. The process is also easily automated, allowing for unmanned operation and further cost reductions.

Airbus

5. Other Benefits

  • Strong and Lightweight Parts The use of material like carbon fiber which has an excellent strength-to-weight ratio, leads to lighter, more robust parts with lesser printing time.
  • Flexible Use of 3D Printers Businesses invest in a 3D printer for a particular project but explore other applications and printing materials giving them more return on investment.
  • Parts Fit Right the First Time Fast, precise, and inexpensive 3D printing iterations ensure that components, especially steel parts where accuracy is paramount, are a perfect fit at the first go.

Go Big With Low Volume Production

Low-volume production thrives in scenarios that are fast-paced, innovative, and cost-efficient. 3D printing's versatility, automation, precision, and efficiency make it a perfect choice. An Ecosystem such as BigRep’s creates a unique environment with innovative 3D printing technology and solutions for low volume production and beyond.

Want to learn more about low volume production empowered by additive manufacturing?

Register to download the eBook, 7 Ways BigRep 3D Printers Unlock Profit Instantly.

Discover how investing in large format additive manufacturing (AM) can revolutionize your industrial business, driving innovation, efficiency and significant cost savings with BigRep’s advanced technology.

DOWNLOAD EBOOK

INDUSTRIAL QUALITY MEETS  COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

How To Pick A 3D Scanner For The Automotive Aftermarket

3D scanner for car customization - feature image

In the realm of aftermarket car customization, automotive 3D scanners can be the overlooked workhorse that brings physical objects into the virtual space. While some car components might have readily available 3D models, designing individualized or original 3D prints needs 3D scanners to recreate an object’s geometry accurately in a simulated environment. The 3D scanner does this by capturing millions of data points from all angles of the part and in minutes you have a complete digital clone of it. This virtual version serves as a three-dimensional test bed to build and iterate concepts swiftly before going into prototyping and production.

3D Scanner car customization

 

Typically, large-format 3D printers come into the picture when printing car parts or bespoke components like dashboards, consoles, and door panels. Coupled with 3D scanning technology, you get visually aesthetic and highly functional parts. 3D scans seamlessly integrate with large-format 3D printers and streamline the process from the outset saving time, effort and money, resulting in exceptional print quality with fewer failed prints.

So How Do You Pick A 3D Scanner That’s A Good Fit For Your Workshop?

To get to the bottom of this, we will explore:

1. Why Is 3D Scanning Important?

3D scanning offers endless possibilities for customization with which you can design and produce components quickly with a high level of precision and accuracy.

Quality Control

The virtual 3D model can be evaluated to make sure every aspect of the part is precisely measured and is within the specified tolerances.

Reverse Engineering

A 3D scanner captures complex geometries with high-quality CAD files when none are available, improving project results by removing the guesswork.

Simpler Prototyping

Modifying and optimizing prototypes digitally before printing them ensures accuracy in producing complex shapes.

Quicker Design Cycles

Scanning the object that the 3D part is being designed for reduces production time and ensures a perfect fit of the 3D-printed part.

Accurate Measurements

Measuring the component, including details in narrow and hard-to-reach spaces, can be scanned for precise dimensions.

Cost-Effective

With 3D scanning, virtual testing reduces the need for physical prototypes. Also, the chances of fewer failed prints bring down costs significantly.

2. How Does 3D Scanning Work?

3D scanners create high fidelity, visual, three-dimensional virtual models by capturing 3D surface data from an object. It uses technologies such as Laser Triangulation, Structured Light Scanning, Photogrammetry, and Time-of-Flight Scanning to recreate the shape, color, and texture of a component digitally. Apart from bringing physical objects into the digital world, you can use the 3D data for inspection, dimensional analysis, reverse engineering, remote part replication, and CAD model validation for 3D printing.

Time-of-Flight Scanners

3. What Are the Different Types Of 3D Scanners?

There are a range of technologies for 3D scanners, and each comes with its advantages, limitations, and cost. The compatibility of different types of 3D scanners with large-format 3D printing depends on factors like scanning range, resolution, scanning speed, and the level of detail necessary for printing the vehicle’s part. Here are the different types of 3D scanners and their potential to integrate with large-format 3D printing:

3D Scanner For The Automotive Aftermarket

1. Laser Triangulation Scanner

This scanner projects a laser line or dot pattern onto the object and captures its reflection angle with sensors to replicate the shape. It is usually used for smaller objects, but it also scans the geometry of larger formats.

2. Structured Light Scanner

A Structured Light Scanner projects light in the form of lines onto the object and analyzes the field of view to generate a 3D model. It works well with large objects as it can capture complex shapes and details and has a large scanning range.

Laser Triangulation Scanners
Time of flight 3D scanner

3. Photogrammetry Scanner

Instead of using active light sources, the Photogrammetry Scanner reconstructs a 3D model digitally with multiple photographs taken from different angles. Photogrammetry is commonly used in large-scale applications like architecture and landscape scanning.

4. Time-of-Flight Scanner

The name "Time-of-Flight" may seem somewhat arbitrary for a camera-like scanner, but it gets its name from the underlying principle it is based on. This scanner emits light and measures the time it takes for the light to bounce back from the object's surface. It can capture large objects easily and is used for large-format 3D printing projects.

Time of flight scanner

4. What Is The Scan-To-Print Workflow?

Scan-to-print workflow is exactly what it says - it’s the steps involved in transforming a 3D scan into a printable model. After capturing the object using a 3D scanner, the 3D data is processed and cleaned with a specialized software. Next, the scanned model is converted into a 3D printable format like an STL file. Finally, the model is prepared for large-format 3D printing by optimizing the orientation, adding support structures, and slicing the model into layers.

STEPS FOR A 3D SCAN-TO-PRINT WORKFLOW

1. Scan the Object

With a high-precision scanner of 100 microns± accuracy, scan the object.

2. Refine the Mesh

Clean up the scan data with scanner software that’ll repair small gaps and simplify the scan.

3. Edit the Model

Refine the 3D model using CAD software by combining multiple scans if necessary.

4. Slice the
File

Translate the 3D model into instructions for the 3D printer with slicing software.

5. Prepare for Print

Set up the printer with the printing filament and configure the device's parameters.

6. Get 3D
Printing

Print the part with an industrial printer perfect for automotive customization like the BigRep STUDIO.

7. Post-Process the Part

Wrap up the process by removing support or excess material, sanding or polishing the part.

STEPS FOR A 3D SCAN-TO-PRINT WORKFLOW

1. Scan the Object

With a high-precision scanner of 100 microns± accuracy, scan the object.

2. Refine the Mesh

Clean up the scan data with scanner software that’ll repair small gaps and simplify the scan.

3. Edit the Model

Refine the 3D model using CAD software by combining multiple scans if necessary.

4. Slice the File

Translate the 3D model into instructions for the 3D printer with slicing software.

5. Prepare for Print

Set up the printer with the printing filament and configure the device's parameters.

6. Get 3D Printing

Print the part with an industrial printer perfect for automotive customization like the BigRep STUDIO.

7. Post-Process the Part

Wrap up the process by removing support or excess material, sanding or polishing the part.

5. What Type of 3D Scanner Is Best for Aftermarket Automotive Customization?

3D scanner for car- structured light

For aftermarket car customization and large-format 3D printing workflows, two commonly used 3D scanning technologies are Structured Light Scanning and Laser Triangulation Scanning. Structured Light gives you high accuracy, making it the perfect choice for capturing intricate car details. While Laser Triangulation captures the overall shape and geometry of larger subjects like car bodies.

A handheld 3D scanner using Structured Light or Laser Triangulation would be the answer for your automotive scanning needs. Handheld 3D scanners offer mobility and flexibility, allowing you to scan objects directly from the car or at any location the vehicle is at. This comes in handy for on-site customizations or restoration projects.

When selecting a handheld 3D scanner, consider factors like scanning accuracy, resolution, ease of use, compatibility with different surface types (reflective or transparent surfaces), and the software used for data processing.

Print Your 3D Scans to Life

2019-10-19_BigRep-Studio-G2_DSC8837_2000px_sRGB

Now it’s time for your design to come to life layer by layer.

This is where BigRep 3D Printers come in. Learn how our 3D printers can give you the transformative power of creating custom car parts that were once concept in your garage. Contact our team today, let us help you THINK BIG!

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

The BigRep STUDIO G2 gets 3D printing off your desk and takes it to the next level. Operating with the same ease as a desktop 3D printer and with 10 times the build volume, the STUDIO G2 provides large-scale industrial manufacturing capabilities in a compact “fits everywhere” build.

Explore the STUDIO

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

The BigRep STUDIO G2 gets 3D printing off your desk and takes it to the next level. Operating with the same ease as a desktop 3D printer and with 10 times the build volume, the STUDIO G2 provides large-scale industrial manufacturing capabilities in a compact “fits everywhere” build.

Explore the STUDIO

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

Leveraging 3D Printing for Automotive Customization at AVI Boston

AVI Boston turns to 3D printing for automotive customization, cutting costs and saving time.

AVI Boston seamlessly weaves technology into crafting personalized and bespoke automotive parts like dashboards, radar installations, door panels, and beyond.

What puts them ahead of the curve is their expertise in integrating cutting-edge audio and visual systems, elevating both the car’s aesthetics and functionality. Their innovative approach is amplified by their use of 3D printing to manufacture end-use parts with BigRep’s STUDIO 3D printer to bring their concepts to life.

Having been in the automotive customization game for over seventeen years, AVI recently approached BigRep to purchase the STUDIO – a large-format 3D printer.

"Finding skilled fabricators and installers is a challenge, but with our STUDIO, it's like having a full-time employee building parts. We design, press print, go away for the weekend and all the parts are ready by Monday morning."

“A big issue we were facing was that we didn’t have enough hands onboard. Finding good fabricator installers is really difficult and now we have a 3D printing machine that does that for us, it's almost like having a full-time employee building a part," said Safi Barqawi, the owner of AVI Boston.

What the STUDIO 3D Printer Brought to the Table

“We can design everything specifically, just press print and we have the entire file on our computer. The cool thing is we have a scan of the door, the dashboard, the center console, design and build it even if the car is not here.” added Safi.

STUDIO G2 features that MOVED the

needle for  AVI BOSTON 

Large Build Volume

The STUDIO G2 boasts of a generous build volume of 1000 x 500 x 500 mm, 10 times that of standard desktop 3D printers. This enables AVI to create sizable quality end-use parts in a single print job, expanding the possibilities for customization.

BigRep STUDIO - Large build volume
BigRep STUDIO Dual Extruder

Dual Extrusion

The ability to print structures with two different materials without having to swap out filaments. The STUDIO G2 eliminates the need for filament changes and opens up possibilities for an uninterrupted seamless print without changing hands.

Reduced Post Processing

Compatible with the STUDIO G2’s dual extrusion system, water-soluble support material BVOH is a revolutionary filament in post-processing. This ecologically friendly advanced material delivers support during print and massively reduces post-processing.

BigRep BVOH Water-Soluble Support Filament
Blade

Digital Inventory

Produce on demand without added costs and uncertainty of keeping stock parts. Instead of stocking up on parts and running the risk of them going to waste, AVI could hit print as needed and create intricate, functional structures like dashboards, doors, center consoles, and cup holders.

Automotive Customization with 3D Printing
Complete auto interiors 3D printed, including panels, doors, cup holders, and more.

How AVI Benefited From BigRep’s STUDIO G2

Works Around The Clock

Having the STUDIO G2 is like having an extra pair of hands in the garage that works without a pause, occasionally needing a bit of grease. “We get five orders, we just press print five times, go away for the weekend, and come back all five prints are ready for us Monday morning” says Safi. “We do a lot of magnetic kits for a specific vehicle and once we design it, we can print it as many times as we'd like without having to recreate the product itself.”

Complex Geometries And Fine Details Come Through

Car parts like custom interior panels and speaker covers need intricate designs that are time-consuming and particularly hard to achieve with traditional machining methods. “With the STUDIO G2, we’ve been designing these parts in-house and building clean structures for such intricate pieces. We would never be able to do that by hand. Getting down to that small of a detail is really hard. What would take days or weeks to get manufactured outside is done in a fraction of the time with the STUDIO.”

Automotive Customization with 3D Printed Car Parts
AVI Boston 3D prints custom car parts with the BigRep STUDIO G2.

Cost Effective Solution

One of the perks of 3D printing in automotive customization is its ability to reduce production costs. With traditional manufacturing processes, tooling and molds are often used resulting in high costs. In comparison, when AVI switched to the STUDIO, it eliminated the need for expensive tooling resulting in reduced production costs, especially when it came to low-volume production and customization.

Intuitive User Interface

“The STUDIO G2 has been nothing but positive all the way around. The machine is extremely easy to use, it's very intuitive, if you want something, you just press print as many times as you want, and it’ll just keep printing it.” The STUDIO is equipped with an intuitive user interface that enables AVI to remotely load gcodes onto the system. The other functions supported by the machine are calibration of the print bed, stop and start operations, and monitoring systems in conjunction with BigRep’s CONNECT. “So, if there are three things that we do all the time, we have three presets on there and you just press print when you are ready for it. It's a very well thought out product backed up by a very good service team.” Safi elaborated.

Assembly of 3D Printed Car Parts
AVI Boston employee examines a newly installed 3D printed door panel.

The BIG Advantage

The conventional way to produce car parts has been highly manual. With the STUDIO, AVI could directly 3D print end-use parts that cost way less and fit perfectly the first time which also helps them stay on top of project timelines. The compact design of the 3D printer was the icing on the cake that enabled AVI to host it right in their workshop. “One of the coolest things about the STUDIO G2 is that it’s sleek and allows us to be super-efficient with the space we have. This gave us the ability to design and print parts with a 3D printer in-house” concludes Safi.

Want to learn more about car customization empowered by additive manufacturing?

Register to watch the on-demand webinar, Digitizing Production of Custom Large-Format Automotive Parts.

Learn how digitizing this process drastically reduces production time and number of stages while saving money and material costs. Also hear from Jeremy Katz, owner of JK Automotive Designs, and see first hand how Katz embraced different technologies, allowing his team to offer more to their clients and continue exceeding expectations. Don't miss out, register for the webinar:

DIGITIZING PRODUCTION OF CUSTOM LARGE-FORMAT AUTOMOTIVE PARTS

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

Massive Benchy 3D Print as a Benchmark for Large-Format 3D Printers

The most frequently 3D-printed object in the world, 3D Benchy, is a 3D model in the shape of a boat that was designed as a benchmark to test all sorts of 3D printing parameters. BigRep put its large-format 3D printers to the test by producing the world's largest Benchy, measuring at 816 mm tall. Let's have a close look at this giant Benchy and what its features can show about BigRep 3D printers' capabilities.

What is a 3D Benchy?

A 3D Benchy is a computer model that is specifically designed to test the capabilities of a 3D printer. Its name derives from "benchmark," which reflects its relevance in 3D printing. The Benchy was first released as an STL file in 2015 and is often the first thing one prints with a new 3D printer it has a set of features that determine the printer's capabilities and possible limitations.

benchy_timelapse_short332_x

Benchy Features

The most common Benchy features include overhangs, bridges, surface finish, and dimensional accuracy. These features are all important in 3D printing, and help evaluate the printer's ability to produce intricate designs, handle complex geometries, and maintain precise measurements. By looking closely at the quality of Benchy prints, one can identify issues or limitations with their 3D printer and make necessary adjustments for better results.

overhang dfam

Overhangs

Overhangs are horizontal or inclined surfaces extending beyond more vertically oriented parts of a 3D print. Successful overhangs showcase the printer's ability to handle complex geometries and maintain structural integrity without supports.

Bridging - Design for Additive Manufacturing

Dimensional Accuracy

The 3D printed Benchy's dimensions can be compared to the 3D model's original specifications. Accurate dimensional reproduction is an important indicator of a printer's ability to maintain precise measurements and avoid scaling issues.

Bridging front view - Design for Additive Manufacturing

Bridges

Bridges are horizontal gaps between two vertical structures. Bridges demonstrates the printer's ability to create even and sturdy horizontal spans, without sagging or drooping in the middle. The length of possible bridges depends on a printer's capabilities, slicing settings, and material used.

Part Orientation - DfAM

Surface Finish

The surface finish of the Benchy model is an essential feature to evaluate. The smoothness, texture, and overall appearance of the 3D printed Benchy can be examined for any imperfections such as layer lines, warping, or inconsistent extrusion, which can affect the final print quality.

Benchy in BigRep PRO

Advantages and Challenges of Printing 3D Benchy

The Benchy is widely recognized in the 3D printing community for its successes and challenges. One of its major strengths is its ability to assess various 3D printing technologies and how they work with various materials. This versatility allows users to evaluate the capabilities and performance of different printers and materials, providing a first-hand understanding of their strengths and weaknesses. Another advantage of using the Benchy is its focus on evaluating print quality and accuracy. By using it as a test model, users can assess the level of detail, dimensional accuracy, and surface finish achieved by their 3D printers. This information is crucial for ensuring the desired level of quality in the final printed objects.

However, where there are opportunities, there are also challenges. One of the major challenges is the time-consuming nature of the test. The benchmark requires printing a complex model, which can be lengthy, resource-intensive, and particularly demanding for users who need quick results or have limited resources at their disposal.

Another limitation of the Benchy is that it may not fully represent real-world printing scenarios. While it is designed to incorporate various features and geometries to challenge printers, it may not capture all the complexities and nuances of real-world objects, potentially leading to limitations in its usefulness as a benchmark for real-world applications.

Benchy in BigRep BLADE
Giant BigRep Benchy

BigRep Benchy Specs

The world's largest Benchy was printed at the BigRep headquarters in Berlin. And while it is definitely a huge 3D print, it was not BigRep's biggest, heaviest, or longest running print.

Here are the printing specs for the BigRep Benchy:

  • Printer: BigRep ONE
  • Material: BigRep PLA
  • Nozzle Diameter: 1.0 mm
  • Layer Height: 0.6 mm
  • Dimensions: 864 x 864 x 816 mm (x, y, z)
  • Printing Time: 121 hours
  • Material Weight: 11.1 kg
Giant_Benchy_Nika_ONE

How Does the BigRep Benchy Measure Up?

While it's a beloved and whimsical 3D model, Benchy does also function as a useful benchmark to evaluate a wide range of 3D printing parameters. Let's have a closer look at the giant Benchy results.

Giant BigRep Benchy Overhangs

Overhangs

The layer height, nozzle diameter, and overall 3D print dimensions greatly effects the quality of overhangs. This gigantic Benchy has large overhangs spanning ranges up to 50 mm long. They were not printed with support to help demonstrate the limits of the printer's capabilities. The BigRep ONE achieved an even, consistent quality with minimal deviations in layer appearance.

Giant BigRep Benchy Dimensional Accuracy

Dimensional Accuracy

Accuracy is highly dependent on what tolerances are required for a part to be acceptable for its use case. There is no noticeable warping of this giant Benchy and only small deviations in layer quality in the most challenging aspects of the print. For a real-world accuracy analysis, a 3D scan of the print can be compared to the original design to determine tolerance.

Giant BigRep Benchy Bridging

Bridges

Some of the bridges in Benchy are too long - in this case, up to 180 mm - to be printed without sagging, and therefore required support. The image above shows the top section of some circular cutouts which were printed without support. There are some slight imperfections, but the overall quality is surprisingly good at such a large scale.

Giant BigRep Benchy Surface Finish

Surface Finish

The more vertically oriented the surface, the smoother the appearance of the layer lines. As a surface is more horizontal, the layers become more pronounced with the appearance of the staircase effect. With a relatively large layer height of 0.6 mm, the differences between vertically and horizontally oriented surfaces is visually apparent.

Conclusion

The Benchy 3D model has become a cornerstone in the world of 3D printing, serving as a reliable benchmark for evaluating the capabilities and limitations of different 3D printers. Its various features, such as overhangs, bridges, surface finish, and dimensional accuracy, provide valuable insights into the printer's ability to handle complex geometries and produce high-quality prints. By closely examining the quality of Benchy prints, users can identify issues with their 3D printers and make necessary adjustments to achieve better results.

However, it is important to acknowledge possible challenges with using the Benchy. The test can be time-consuming and resource-intensive, which may not be ideal for users who require results very quickly or have limited resources, such as filaments. Moreover, the model may not fully capture the complexities and nuances of real-world printing scenarios, potentially limiting its usefulness in certain applications.

Nevertheless, the Benchy remains a valuable evaluation tool within the 3D printing community. It provides a comprehensive assessment of printer capabilities, highlights potential areas for improvement, and allows users to make informed decisions when selecting printers and materials for their projects. By understanding its strengths and limitations and using it with other evaluation methods, users can maximize the benefits of the Benchy for their specific printing needs and applications.

Want to learn more about large-format additive manufacturing?

Register to download the eBook, Guide to Integrate Large-Format Additive Manufacturing.

Learn how Increasing the build size increases the possibilities for builds: users can create larger parts, removing the constraints of more standard sizes of build envelopes. 3D printing a large part all at once means less time is spent designing around multiple print jobs, less time assembling multiple parts, and more time getting those parts to work for you. Don't miss out, download the eBook today:

GUIDE TO INTEGRATE LARGE-FORMAT ADDITIVE MANUFACTURING

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

About the author:

Nika Music <a style="color: #0077b5" href="https://www.linkedin.com/in/nika-music-2301/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Nika Music

Digital Marketing Specialist

Nika is a Social Media Manager with a background in the philosophy of technology. After obtaining their MA, Nika's passion and expertise in this field naturally guided them towards the exciting world of 3D printing. Currently, Nika is thriving at BigRep, enhancing the company's social media presence and creating brand awareness.

How to Overcome Six Common Manufacturing Challenges

Whether you are an experienced manufacturer or a new entrepreneur, the business landscape is continually evolving with greater acceleration and more significant changes.

In this article, we will consider six common challenges for manufacturers and how they can be overcome with smart solutions that really work. By anticipating these issues rather than firefighting problems as they arise, you can secure a more sustainable business model to scale your business and grow revenue.

Let’s explore six manufacturing challenges producers face and how you can ensure success for your business.

1. Lack of Skilled Workers

CHALLENGE

A troubling trend is steadily rising around the globe: the lack of skilled workers in the manufacturing sector. This is the product of lower employment rates in many countries, an aging workforce, a lack of tech-savvy labor, and the effects of the COVID-19 pandemic, just to name a few factors. A report by The Manufacturing Institute and Deloitte Consulting concludes that 22% of workers in U.S. manufacturing will be retiring in the next ten years. Additionally, they predict that the manufacturing skills gap could result in 2.1 million unfilled jobs by 2030. A report by Eurofound in 2019 found that Europe is not exempt from these struggles, as 39% of European manufacturing companies reported that their production was limited by labor shortages. This year, the German Chambers of Commerce and Industry (DIHK) explained that more than half of Germany's companies struggle to fill vacancies due to a lack of skilled workers.

SOLUTION

The accessibility of 3D printing technology, also known as additive manufacturing, allows a broader range of workers, including those with limited traditional manufacturing skills, to aid in product development, low-volume production, and full-scale manufacturing. 3D printing simplifies the production process by creating complex parts and prototypes directly from digital designs, carrying out intricate manufacturing processes with minimal human intervention. This reduces the need for highly skilled labor to operate machinery and perform manual tasks.

One solution to simplify the digital design process is scanning an existing part to create a 3D model, which can be 3D printed. Another option is using a design configurator to customize and adapt 3D-printable designs without needing in-depth design expertise. To learn more about design configuration, have a look at BigRep FLOW configurator apps.

BigRep PRO 3D Printer

2. Inventory Management

CHALLENGE

Inventory management can be a real puzzle for manufacturers. Picture this: You've got to predict what customers want, but their desires are like a roller coaster, up and down. Plus, suppliers might send things late, putting your production on hold. Holding onto too much inventory costs you money, but running out is a disaster. And don't forget about products that can go bad or become outdated fast. It gets even trickier when you have many different products to handle, and deciding which ones to keep or drop is no simple task. Then there's the balancing act between having just enough inventory when you need it and keeping extra in case things go unexpectedly.

Forbes reports that today’s average manufacturing company carries thirty days more inventory than at the beginning of 2007. While adequate inventory is a crucial buffer for supply chain issues, it is also the primary source of waste for companies. Holding excess inventory ties up capital and incurs costs such as storage, insurance, and depreciation. In a world where everything is always changing, figuring out how to handle your inventory is like playing a game of strategy to stay ahead in the manufacturing world.

SOLUTION

As a means of rapid production, 3D printing allows for just-in-time manufacturing, where parts are produced precisely when they are needed. Thanks to significantly reduce lead times compared to traditional manufacturing methods, you can quickly respond to changes in customer demand to deliver on time. Often called the digital warehouse, 3D designs can be stored on a cloud or server to be 3D printed once an order is placed. This also reduces the risk of overproduction and minimizes the cost of holding excess inventory. The number of business 3D printing components, products, and spare parts on demand is steadily increasing with early adopters such as Deutsche Bahn, Bentley, Miele, and Shell, leading the way. If you want to learn more about 3D printed spare parts on demand, read the eBook Deutsche Bahn Goes Additive with BigRep.

3d-printer-prediction

3. Supply Chain Dependency and Transparency

CHALLENGE

As a manufacturer, you always depend on suppliers for materials, components, and services. However, each supply chain dependency introduces a potential risk of delays, lack of availability, or price increases. As your business grows, so do the potential risks of supply chain failures along with the complexity of logistics. And as we saw with the global supply chain gridlock during COVID-19, one issue can have massively far-reaching repercussions.

In addition to these practical supply chain concerns, consumers increasingly demand greater manufacturing transparency from companies. Today's customers prioritize quality and ethically produced items, plus they're willing to spend more for those products. A study conducted by researchers at the MIT Sloan School of Management revealed that consumers may be willing to pay an additional 2% to 10% for products with greater supply chain transparency. So, not only do manufacturers need to manage their supply chains to keep their business running, but they must also consider how those supplier choices will affect consumer confidence. 

SOLUTION

With additive manufacturing, companies can produce locally, reducing dependence on distant suppliers and minimizing the impact of global disruptions. By using a digital warehouse, you can even produce locally with distributed manufacturing from afar: send your 3D file to be printed on location wherever the part is needed, With greater control of your supply chain, you also have more influence over lead times and fewer unexpected or increased costs. 

By implementing 3D printing for in-house production, tracking and controlling your supply chain is much easier, allowing you to satisfy consumers' growing demand for transparency. You own your own production process, plus fewer steps and logistics require oversight. Localized manufacturing can allow more environmentally friendly production with reduced shipping and other logistics. For more information about how 3D printing can reduce supply chain dependency, read the eBook How to Reduce Lead Times with In-House Supply Chains.

Design for Additive Manufacturing (DfAM)

4. Mass Customization

CHALLENGE

An increasing number of industries and businesses are embracing the trend of mass customization. This movement encompasses well-established brands that have introduced customization features to expand their product offerings and boost their sales. It also includes niche manufacturers and startups, which benefit from not having costly legacy factories and intricate supply chains. Forbes claims that custom products are the future of small and medium-sized businesses, and The Deloitte Consumer Review reported that more than 50% of consumers showed interest in purchasing personalized products.

Customers are willing to pay more for unique products, and traditionally, manufacturers also spend more to produce them. For example, many plastic products are produced using expensive CNC-milled molds. This is cost-effective at scale, but the costs skyrocket for low-volume and unique production. Manufacturers are faced with the challenge of how to produce customized products at scale in a cost-effective way.

SOLUTION

With additive manufacturing, there are no added costs in unique and low-volume production. That means you can print identical or modified products, and the only factors changing the manufacturing costs are material usage and printing time variations. You have the greatest freedom of customization without added costs when 3D printing end-use parts and products. While traditional tooling, such as CNC-milled molds, is durable and long-lasting, the cost is prohibitive for single or limited use. 3D printed tooling may be less durable but can be the perfect solution for limited production and robust enough to get the job done. Read this blog to learn more about mass customization and the power of 3D printing.

Airbus

5. Scaling Your Business

CHALLENGE

One of the most unexpected challenges that manufacturers encounter is choosing the right time to scale your business.  Scale up too early and you risk financial strain, operational challenges, and loss of quality. Scale too late and risk market saturation, missed opportunities, and a competitive disadvantage to more established companies. To decide when the time is right, you need to ask yourself the right questions. Is your product ready for market? If your product is not performing well, do you need to pivot the product offering or redesign it? Do you have the capacity to meet production requirements if demand increases? 

SOLUTION

To ensure adequate quality, good product-market fit, and best product offering, you need to iterate your product design. With traditional production methods, this typically requires outsourcing and/or hand-made prototypes, and unfortunately, both of these are expensive and slow to produce. 3D printing is widely accepted as the best solution for rapid prototyping, so much so that the two are practically synonymous. Additive manufacturing lets you quickly produce a design or functional prototype, make changes as needed, and reprint until your product is perfect.

Large-format 3D printing also allows you to produce larger prototypes in full scale. If you find that your product is not performing well after you launch, you can repeat the iteration cycle to change the product as needed. And what if your product is perfect and demand is high? 3D printing can help you meet those demands with in-house production, simplified logistics, and reduced supply chains.

In short, additive manufacturing lets you get to market faster, plus it helps you ramp up production. To see some success stories of how 3D printing helped companies iterate fast, produce faster, and get to market faster, see the webinar Improve Time To Market for Commercial Vehicles.

Nowlab BigRep Gripper 3d printed

6. Keeping Up With Automation

CHALLENGE

New technological advancements seemingly occur every day, increasing demand and putting pressure on manufacturers to fulfill larger orders. Automation boosts productivity, increases quality, saves costs, and perhaps most importantly, it can collect and analyze data to influence decision-making for continually improved outcomes. The robotic process automation market was valued at $2.3 billion in 2022 and is expected to grow at a CAGR of nearly 40% from 2023 to 2030. This is concerning for small and medium businesses as they compete with large corporations that can afford to use AI to make their production lines more efficient. As automation has taken a foothold, it simply cannot be ignored as the future of manufacturing. 

SOLUTION

A digitized workflow can help your business catch up to the automation super trend, and 3D printing can play a huge part in that. The key is choosing what processes and technologies need updating and how to integrate those within an existing workflow to become more agile and efficient.

Consider digitizing your prototyping process to iterate faster with more data-driven design iterations. Once in full production mode, you might produce 3D printed tooling to streamline your production process. Perhaps you choose to scan components to create perfectly customized 3D printed tools. Maybe you want to embed technology like sensors into those custom tools to provide valuable feedback during production. With an industrial 3D printer, you can expect reliable results with automation across the calibration and printing phases. You might incorporate 3D printing with robotics, milling, or AI so that the strengths of each technology can truly shine as part of an intelligent, automated solution.

Conclusion

3D printing is a transformative solution for manufacturing challenges. It simplifies complex processes, reducing the need for highly skilled workers. It also enhances supply chain resilience through localized, on-demand production, streamlines inventory management by minimizing stock needs, and enables cost-effective mass customization. With 3D printing, scaling your business becomes flexible and efficient, and automation seamlessly integrates into production, boosting productivity while cutting labor costs. Embrace 3D printing for a more agile, efficient, and future-ready manufacturing approach.

Want to learn more about manufacturing challenges overcome by adopting additive?

Watch the on-demand webinar Maximize Efficiency for Localized Production.

Learn how additive manufacturing can make a huge impact to reduce production costs and speed up manufacturing times. Particularly for low-volume and custom parts, highly skilled labor and outsourcing can massively inflate costs and lead times. Learn how large-format 3D printing can streamline processes, simplify logistics, and minimize supply chain risks to deliver the biggest business impact. Don't miss out, register for the webinar:

MAXIMIZE EFFICIENCY FOR LOCALIZED PRODUCTION

INDUSTRIAL QUALITY MEETS  COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

About the author:

Lindsay Lawson <a style="color: #0077b5" href="https://www.linkedin.com/in/lindsay-lawson-152a69185/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Lindsay Lawson

Head of Product Marketing

With an MFA in New Genres, Lindsay's background in sculpture and animation eventually led her to the world of 3D printing. She is primarily focused on applications using large-format 3D printing with additional emphasis on post-processing techniques and design for Additive Manufacturing.

How to 3D Print Channel Letters and Signs

3D Printed Illuminated Sign

Channel letter manufacturers face a rapidly changing industry landscape. Traditional methods are reliable, but 3D printing offers a new level of efficiency and customization. By adopting 3D printing, manufacturers can enhance production speed, reduce costs, and meet diverse client demands.

This article explores the benefits and implementation of 3D printed channel letters.

The Basics of 3D Printing for Channel Letters

What is 3D printing? 

3D printing, or additive manufacturing, is a process that transforms digital designs into physical, three-dimensional objects. By depositing material layer upon layer, 3D printers can recreate intricate designs with precision and accuracy. This technology has found applications in various sectors, from healthcare to automotive, and now, in the realm of business signage. 

Why 3D printing for channel letters? 

The primary allure of 3D printing for channel letters lies in its unparalleled flexibility. Traditional signage methods can often be limiting, especially when it comes to custom designs or rapid modifications. In contrast, 3D printing offers the ability to produce bespoke designs tailored to a business's unique brand identity. This means that businesses can now have signage that is not only functional but also a true reflection of their brand ethos. 

BigRep ONE Large-Format 3D Printer

The Simplicity of the 3D Printing Process

1. Designing Your Channel Letters

The first step in the 3D printing journey is creating a digital design. With the advent of intuitive software tools, even those with minimal design experience can craft a digital model of their desired signage. These tools allow for easy adjustments, ensuring that the final product aligns perfectly with the business's vision. 

2. Choosing the Right Material

Material selection is crucial in determining the durability and aesthetic appeal of the final product. For 3D printed signage, there's a wide array of materials to choose from, ranging from robust plastics to metals. Each material comes with its set of advantages, allowing businesses to select one that best suits their needs and budget. 

3. 3D Printing and Post-Processing

Once the design is finalized and the material selected, the actual printing process begins. Modern 3D printers are efficient, translating digital designs into physical objects with remarkable precision. After printing, some post-processing might be required, such as sanding or painting, to enhance the appearance and longevity of the channel letters. 

Channel Letters - CAD Design

Designing Your Channel Letters

Designing for 3D printing might seem daunting, but with the right approach, it can be a seamless process: 

Software Selection: Start by choosing a 3D modeling software that aligns with your skill level. Beginners might find tools like Tinkercad or SketchUp user-friendly, while those with more experience might opt for software like Blender or Fusion 360. 

Typography Matters: When designing channel letters, ensure you select a font that is legible and aligns with your brand's identity. Remember, thicker fonts tend to be more durable and easier to print. Consider the 3D printer’s capabilities regarding the dimensions of your sign; for example, very thin letters may not be printable. 

Scaling and Dimensions: Ensure your design is to scale. Measure the space where the sign will be placed and adjust your digital model accordingly. This ensures that the final print fits perfectly in its intended location.  

Save in the Right Format: Once your design is complete, save it in a format compatible with your 3D printer, typically .STL or .OBJ. 

Filament Material Samples
BigRep Filament Material Samples

Choosing the Right Material

Selecting the appropriate material is paramount, as it dictates the longevity, appearance, and overall effectiveness of your channel letters: 

PLA (Polylactic Acid): A popular choice for 3D printing, PLA is bio-based, user-friendly, and cost effective. Available in a myriad of colors, it's perfect for indoor signs due to its sensitivity to UV rays and high temperatures. 

ASA (Acrylonitrile Styrene Acrylate): Known for its exceptional UV resistance and durability, ASA is an excellent choice for outdoor signage. It retains color and mechanical properties even when exposed to prolonged sunlight, making it superior to ABS for outdoor applications. While it offers a finish similar to ABS, it's essential to note that ASA requires a heated print bed and might be a bit more challenging to print with than PLA. 

PETG (Polyethylene Terephthalate Glycol): Merging the printability of PLA with the resilience of ASA, PETG stands out as a versatile choice. Its UV resistance and strength make it suitable for both indoor and outdoor channel letters. In addition, PETG has the highest light transmission of the commonly used FFF materials. This can be a benefit when producing channel letters and signage.

Consider Finish and Durability: When deciding on a material, factor in the environment your sign will be placed in. For outdoor signs, UV-resistant and waterproof materials like ASA and PETG are ideal. Also, envision the desired finish—whether glossy, matte, or textured—and select your material to achieve that effect. 

BigRep Fiber-Ready PEX (Power Extruders)
3D Print Post Processing Powder Coating

3D Printing and Post-Processing

Once you've settled on a design and chosen your material, it's time to bring your channel letters to life. 

Printer Calibration: Before starting, ensure your 3D printer is calibrated. This means checking that the print bed is level, the nozzle is clean, and the temperature settings align with your chosen material. For instance, ASA usually requires a higher extruder temperature than PLA. 

Support Structures: Depending on the complexity of your design, you might need to add support structures. These temporary structures help in printing overhangs or intricate details and can be removed post-printing. The support structures can be created during slicing when you make your 3D printing file, called gcode. Slicing software like BigRep BLADE can automatically create the needed support structures from default settings. 

Layer Resolution: Decide on the layer height for your print. A smaller layer height will give a smoother finish but will take longer to print. Conversely, a larger layer height is quicker but might require more post-processing to achieve a smooth appearance. 

Post-Processing: After printing, some cleanup and finishing touches might be necessary. This can include: 

  • Support removal: To remove the support structures, by either breaking them off manually or dissolving them if you use water-soluble support material, like BigRep BVOH. 
  • Sanding: To smooth out layer lines or imperfections. 
  • Painting or Sealing: Especially if you want a specific color or need additional protection against the elements. 
  • Assembly: If your sign consists of multiple parts, you'll need to assemble them, which can be done using strong adhesives or other joining methods. 
Break Off Support Structures
Support structures are designed to break away easily after 3D printing.

Cost Implications for 3D Printing Channel Letters

Initial Investment

While there's an upfront cost associated with purchasing a 3D printer, materials, and software, the long-term benefits often outweigh these initial expenses. When compared to the recurring costs of traditional signage methods, especially for custom designs, 3D printing can offer substantial savings. 

Long-Term Savings

The ability to print in-house eliminates the need for outsourcing, reducing lead times and costs. Moreover, the flexibility of 3D printing means that design alterations can be made swiftly without incurring significant expenses. This adaptability is especially beneficial for businesses that require seasonal or promotional signage changes. Aside from creating 3D printed channel letters, a 3D printer can be used to make virtually anything, so if you have one in house, you will surely find many additional applications that are made simpler and less expensive with 3D printing. 

Real-Life 3D Printing Success Stories

ProLicht Makes Complex and Custom 3D Printed Signs

ProLicht develops and produces solutions for illuminated advertising and complex advertising installations for brands and corporate designs worldwide. They rely on modern technological, including their BigRep ONE, to be able to create highly individualized products with superior quality.

The BigRep ONE is integrated into ProLicht's streamlined workflow with 95% in-house production. This guarantees quality management so that control of implementation is almost exclusively in their our hands.

ProLicht boasts a complete portfolio that meets all requirements for inside and outside CI/CD of global brands.

Through quality and sustainability in the development, production, and installation of their signware solutions, ProLicht can create long-lasting value.

BigRep Headquarters Illuminated Channel Letters

The BigRep creative team shows how they 3D printed a large-scale customized sign with the size, font, and color of their choice. The sign was designed to be printed on a BigRep ONE without any support filament, which made the print very fast and inexpensive. With dual extrusion, two different filaments (one colored and one transparent) are integrated into a single print to blend the branded colors with light diffused through the transparent material.

Tips and Tricks for 3D Printing Channel Letters

Maximizing the Lifespan of Your 3D Printed Channel Letters

Regular maintenance can extend the life of your sign. This includes periodic cleaning to remove dust and debris and checking for any signs of wear or damage. If your sign is outdoors, consider applying a UV-resistant sealant to further protect against the elements. 

Creative Ideas

3D printing offers a realm of possibilities. Think beyond just letters. Incorporate logos, symbols, or even interactive elements into your signage. With 3D printing, you're only limited by your imagination. 

Maintenance and Care

Ensure your sign is securely mounted to prevent any damage from strong winds or other external factors. Regularly inspect for any signs of wear or damage and address any issues promptly to maintain the sign's integrity and appearance. 

3D Printed Channel Letters
3D Printed Sign by ProLicht

The world of business signage has been transformed by the capabilities of 3D printing. For manufacturers, this technology offers an avenue to create distinctive, durable, and cost-effective signage that truly resonates with their brand's identity. As the world of 3D printing continues to evolve, it's a well-timed moment for businesses to embrace this innovation and stand out in a competitive market. 

Embracing innovation is the hallmark of a forward-thinking business. If you've been inspired by the potential of 3D printed channel letters, now is the time to take the leap. Whether you're just starting out or looking to revamp your existing signage, 3D printing offers a world of possibilities. 

Have you already ventured into the realm of 3D printed signage? Or perhaps you're teetering on the edge of making the decision?  

Get in touch! Let's redefine the future of business signage! 

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

About the author:

Dominik Stürzer <a style="color: #0077b5" href="https://www.linkedin.com/in/dominik-stuerzer/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Dominik Stürzer

Head of Growth Marketing

Dominik is a mechanical engineer whose passion to share knowledge turned him to content creation. His first 3D prints started in university. Back then the 3D printers were big on the outside and small on the inside. With BigRep the machines are finally big in their possibilities.

How 3D Printing is Changing Hydraulic Engineering

3D Printed Weir in Hydraulics Lab at Helmut Schmidt University

Ever wondered how top hydraulic engineers optimize river systems without real-world risks?

Step into the advanced hydraulics lab at Helmut Schmidt University. Here, Dr. Mario Oertel and his team are transforming weir designs with the BigRep ONE 3D printer, turning digital concepts into tangible prototypes swiftly.

This fusion of time-honored hydraulic research and contemporary technology is redefining water management. The lab, discharging 1,500 liters per second through a scaled river model, goes beyond computer simulations to test and iterate weir designs, ensuring both precision and cost-efficiency.

Discover how this blend of traditional hydraulic research and modern tech is shaping the future of water management.

What is a Weir?

A weir is a lateral structure commonly used in open channel flow systems, such as rivers, streams, canals, and hydraulic laboratories, to measure and control the flow of water. It is a simple and versatile device that helps regulate water levels, monitor flow rates, and study fluid behavior. Weirs are designed to create a specific flow condition by constraining the water flow, causing it to spill over the top of the weir crest.

Weirs have a wide range of applications, including water level regulation, flood control, irrigation management, environmental monitoring, and hydraulic research. There are several types of weirs, each with different shapes and purposes. Common types include rectangular weirs, triangular weirs (V-notch weirs), trapezoidal weirs, and piano key weirs which are used in the hydraulics lab at the Helmut Schmidt University.

A fixed-crest ogee weir in Berlin, USA
A fixed-crest ogee weir in Berlin, USA

Digital Simulation vs Physical Experiments

Researchers and engineers at the Helmut Schmidt University conduct experiments and studies related to fluid mechanics, hydraulic systems, and fluid behavior as part of the civil engineering program. The hydraulics lab is equipped with various apparatus and instruments to investigate how fluids behave under different conditions, pressures, and flow rates. One focus of research is novel weir designs, which are tested in a river system scaled model: a one meter wide flume fitted with design prototypes.

By developing and testing new weir designs in the hydraulics lab, researchers can create more efficient weirs that can have a greater impact when integrated into river systems. Digital simulation is a powerful tool for researchers, but there are limits to what simulation alone can achieve. Using physical experiments with 3D-printed weirs offers several distinct advantages such as:

Real-world Validation:

Physical experiments provide direct validation of simulation results. Comparing actual measurements from the 3D-printed weir prototypes with simulated data helps validate the accuracy of the simulation model and the assumptions used.

Physical Interaction:

Researchers can observe the behavior of the flow, the water surface, and the interaction with the weir structure in real time. This hands-on experience provides valuable insights that might not be captured in simulations.

Fluid-Structure Interaction:

These experiments can capture intricate fluid-structure interactions, such as vortex shedding, eddies, and turbulence, which might be challenging to accurately simulate.

Unforeseen Phenomena:

Unexpected or complex phenomena may arise during physical experiments that were not anticipated in simulations. These phenomena can lead to new insights and discoveries.

Quantitative and Qualitative Data:

Offering a dual perspective, physical experiments churn out both quantitative (like flow rates and velocities) and qualitative data (visual observations), enriching the understanding of weir behavior.

Sensor Calibration and Verification:

To ensure accurate data collection, these experiments help to calibrate and verify measurement tools and sensors in the laboratory.Innovation and Optimization

Innovation and Optimization:

Physical experiments can spark innovation and lead to the discovery of new and optimized weir designs that might not have been considered in simulations alone.

Complex Geometries:

3D printing enables the creation of complex and customized weir geometries that may be challenging to simulate accurately. Physical prototypes can be designed and manufactured with greater freedom and creativity.

Hydraulics Lab at Helmut Schmidt University
Hydraulics Lab at Helmut Schmidt University

3D Printed Weirs for Hydraulics Research

One project by the hydraulic engineering researchers at the Helmut Schmidt University focuses on piano key weirs, so named for their resemblance to the keys on a piano. Piano key weirs are designed to efficiently manage high flow rates and prevent flooding while taking up less space than conventional weirs. This makes them particularly useful in urban and confined environments.

While weir prototypes would traditionally be constructed from laser-cut acrylic glass that must be manually glued together, Dr. Mario Oertel turned to large-format 3D printing for a better solution. By 3D printing the weirs, researchers were able to quickly see their prototypes in action while cutting costs in the process. The BigRep ONE 3D printer also allowed them to easily iterate new designs and test them in the hydraulics lab within days.

Dr. Mario Oertel, Professor of Hydraulic Engineering at Helmut Schmidt University, with the BigRep ONE
Dr. Mario Oertel, Professor of Hydraulic Engineering at Helmut Schmidt University, with the BigRep ONE

Advantages of 3D Printing Weir Prototypes

Rapid Prototyping:

3D printing allows for quick and cost-effective production of weir prototypes. Researchers can design, iterate, and test multiple designs in a short period, speeding up the research and development process. Traditional manufacturing methods often involve longer lead times due to the need for tooling and setup. 3D printing minimizes lead times, enabling researchers to conduct experiments and gather data sooner.

Ease of Iteration:

Researchers can easily create custom weir designs tailored to specific objectives. This flexibility enables the exploration of various geometries, sizes, and configurations that might be challenging or expensive to achieve using traditional manufacturing methods. To test different parameters and variables, researchers can easily modify and print multiple iterations of weir prototypes. This iterative testing process can lead to more refined and optimized designs.

Complex Geometries:

3D printing enables the creation of intricate and complex geometries that may not be feasible with traditional machining methods. This is particularly useful for exploring novel weir shapes and designs.

Cost Savings:

Traditional machining methods can be expensive, especially for small-batch or one-off prototypes. 3D printing reduces material waste and production costs, making it more cost-effective for research purposes. After a slight learning curve, the researchers in the hydraulics lab were able to adjust slicing parameters in BigRep BLADE to reduce material usage by more than 60%.

Reduced Lead Time:

Traditional manufacturing methods often involve longer lead times due to the need for tooling and setup. Typical weir prototypes are constructed from acrylic glass, which is time consuming and expensive to produce. 3D printing minimizes lead times, enabling researchers to conduct experiments and gather data sooner.

Material Selection:

BigRep offers a wide range of filaments, plus BigRep 3D printers are open for third party filaments, allowing researchers to choose materials that balance research requirements with print quality and affordability. This is especially important in hydraulics research where accurate material properties can impact prototype behavior. Researchers at the Helmut Schmidt University hydraulics lab found great results printing weirs with BigRep PLX because it is easy to print, affordable, and produces beautiful surfaces.

Educational Tool:

3D-printed weir prototypes provide a tangible representation of theoretical concepts, making it easier for researchers and students to understand and visualize fluid flow patterns, velocity profiles, and other hydraulic phenomena. They can also be equipped with sensors and instrumentation to collect data during experiments. This data can be used for analysis, validation, and calibration of hydraulic models.

3D Printed Weir in Hydraulics Lab at Helmut Schmidt University
3D Printed Weir in Hydraulics Lab at Helmut Schmidt University

Large Format 3D Printing in Research Institutes

While the BigRep ONE is placed within the hydraulics lab of the Helmut Schmidt University, other departments and students can access the large-format 3D printer for additional research and projects. This facilitates collaborative projects involving students and faculty from different departments, encouraging interdisciplinary learning and problem-solving. Additionally, familiarity with large-format 3D printers equips students with skills and knowledge that are increasingly valuable in the many industries adopting additive manufacturing.

Having a large-format 3D printer in a university can enhance the learning experience, foster innovation, and prepare students for the evolving demands of modern industries. It serves as a versatile tool that encourages creativity, problem-solving, and collaboration across various academic disciplines.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. With over 500 systems installed worldwide, it's a trusted tool of designers, innovators, and manufacturers alike. With a massive one-cubic-meter build volume, the fast and reliable ONE brings your designs to life in full scale.

Explore the ONE

About the author:

Lindsay Lawson <a style="color: #0077b5" href="https://www.linkedin.com/in/lindsay-lawson-152a69185/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Lindsay Lawson

Head of Product Marketing

With an MFA in New Genres, Lindsay's background in sculpture and animation eventually led her to the world of 3D printing. She is primarily focused on applications using large-format 3D printing with additional emphasis on post-processing techniques and design for Additive Manufacturing.

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