How 3D Printing is Changing Hydraulic Engineering

April 29, 2024August 22, 2023

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

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

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

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

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.

Explore the ONE

About the author:

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.

The Power of Gyroid Infill in 3D Printing: Strength, Efficiency, Precision

September 7, 2023July 26, 2023

Improve your 3D prints with gyroid infill, a structure that strengthens, lightens, and enhances design. This guide covers benefits, strategies, and applications to help you achieve the best results.

You'll learn:

What is gyroid infill?
Advantages of gyroid infill
How to use gyroid infill

What is a Gyroid?

A gyroid is a fascinating mathematical shape known as a triply periodic minimal surface. It was discovered by physicist Alan Schoen in 1970 and has since become a popular infill pattern in 3D printing.

To understand a gyroid, imagine a complex network of twisted and interconnected tubes. These tubes form a repeating pattern that extends infinitely in all directions without intersecting or overlapping. The result is a continuous lattice structure that fills up space in a unique and captivating way.

The gyroid pattern exhibits a remarkable balance between complexity and symmetry. It features self-replicating motifs that create an intricate and interconnected lattice. This intricate geometry is what gives gyroid infill its exceptional properties.

While understanding the mathematical intricacies of a gyroid can be complex, 3D printing software simplifies the process of creating this pattern automatically. By leveraging the power of intelligent 3D printing software, you can easily implement gyroid infill and harness its unique properties for your 3D prints.

Digital Model of a Gyroid Structure

Understanding Gyroid Infill:

The gyroid infill pattern is renowned for its exceptional strength-to-weight ratio. Due to its intricate interlocking geometry, it provides excellent load-bearing capabilities, making it ideal for parts that require durability and resilience. Whether you're prototyping functional components or creating intricate art pieces, gyroid infill ensures that your prints can withstand the test of time.

In addition to its strength, gyroid infill is known for its material efficiency. By utilizing its interconnected channels, it reduces material usage without compromising structural integrity. This characteristic is particularly advantageous when printing larger objects that can become overly heavy and use large amounts of material or when cost-effective production is a priority. With gyroid infill, you can achieve lightweight 3D prints while minimizing waste, making it an eco-friendly choice for sustainable manufacturing practices.

Gyroid infill is a great choice for creating visually appealing 3D prints, thanks to its intricate and organic pattern. The interlocking tubes create a mesmerizing visual effect that adds a unique touch to your 3D prints. This can be particularly striking in 3D prints that are sliced without perimeter walls, making the gyroid infill fully visible.

Advantages of Gyroid Infill in 3D Printing:

Low warping:

Unlike other infill patterns, the curved lines of the gyroid infill do not provide a specific direction for plastic shrinkage. This unique characteristic helps to distribute the stresses and forces evenly throughout the print, reducing the likelihood of warping. Eliminating the directional bias enhances the overall stability and dimensional accuracy of 3D printed objects.

Enhanced Strength and Structural Integrity:

Gyroid infill exhibits exceptional strength and structural integrity due to its interlocking lattice structure. The complex network of interconnected channels distributes forces evenly throughout the print, minimizing the risk of failure and improving overall stability. This makes gyroid infill suitable for load-bearing applications that require durability and resistance to external forces.

Significant Weight Reduction:

One of the standout advantages of gyroid infill is its ability to achieve significant weight reduction in 3D printed objects. The intricate lattice structure optimizes material usage, creating a lightweight yet robust internal framework.

Material Efficiency and Cost Savings:

Gyroid infill is highly efficient in terms of material usage. The interconnected channels and intricate lattice pattern reduce the volume of material required for the infill, minimizing material waste and lowering costs. This is particularly valuable when working with expensive or high-volume materials, as gyroid infill maximizes material efficiency without compromising strength or structural integrity.

Improved Heat Dissipation:

The gyroid lattice structure provides excellent heat dissipation properties. The interconnected channels allow for efficient airflow, aiding in the cooling process during printing. Improved heat dissipation helps prevent warping, deformation, or other thermal issues, resulting in more reliable and dimensionally accurate prints.

Enhanced Flexibility and Impact Resistance:

The intricate lattice structure of gyroid infill offers a unique advantage in terms of flexibility and impact resistance. The interlocking nature of the lattice allows for controlled flexing and absorption of energy upon impact, making 3D printed parts more resistant to breaking or cracking. This property is beneficial for parts that undergo stress or require a certain degree of flexibility, such as protective cases, sports equipment, or wearable accessories.

Excellent Filament Flow:

The gyroid infill pattern facilitates smooth and consistent filament flow during printing. The continuous, interconnected channels enable efficient material distribution, reducing the chances of clogs or inconsistent extrusion. This results in improved 3D print quality, accuracy, and reliability, contributing to successful prints with fewer defects or issues.

By leveraging these advantages, gyroid infill unlocks new possibilities in 3D printing, allowing for stronger, lighter, more cost-effective, and visually appealing prints.

Different Infill Patterns

Disadvantages of Gyroid Infill in 3D Printing:

While gyroid infill offers numerous advantages, it is important to consider its potential disadvantages as well:

Longer Slicing Times

Each layer must be meticulously computed and mapped to the interlocking channels of the gyroid infill. Consequently, the slicing software needs to process more data and perform additional computations, resulting in longer slicing times.

Limited Control Over Internal Geometry:

The complex nature of the gyroid grid can make it difficult to incorporate specific internal features or structures into the print. Unlike lattice infill patterns, gyroid infill may limit the ability to create precise internal geometries or incorporate functional features such as internal channels or compartments. If your print requires precise internal designs or specific functionality, gyroid infill may not be the best option.

Reduced Transparency and Visual Clarity:

If transparency or visual clarity is desired in your print, gyroid infill may not be the best choice. The complex structure of gyroid infill can obstruct light transmission and result in reduced transparency. This limitation may not be suitable for applications that require optical clarity or the ability to see through the 3D printed object.

Understanding these potential disadvantages will help you make informed decisions when choosing infill patterns for your 3D prints.

The rotor blade’s gyroid infill printed by the BigRep ONE at the maker space of TH Wildau.

Applications and Use Cases:

The versatility of gyroid infill opens up a wide range of applications and use cases where its unique properties shine. Here are a few areas where gyroid infill has proven to be particularly advantageous:

Functional Prototypes:

When creating prototypes for functional testing, gyroid infill offers the perfect balance of strength, weight reduction, and material efficiency. It ensures that prototypes can withstand rigorous testing while minimizing material costs.

Mechanical Components:

Parts that require durability, stability, and resistance to external forces benefit greatly from gyroid infill. Whether it's gears, brackets, or structural supports, gyroid infill enhances the overall performance and longevity of these components.

Lightweight Structures:

Industries such as aerospace, automotive, and robotics often require lightweight components to improve performance and efficiency. Gyroid infill helps achieve these goals by reducing weight without compromising strength or structural integrity.

Artistic and Decorative Prints:

The visually captivating nature of gyroid infill makes it an excellent choice for artistic and decorative prints. From intricate sculptures to visually appealing art pieces, gyroid infill adds a unique aesthetic dimension to the finished prints.

3D Printed Tray Made without Walls

Implementation and Tips for Using Gyroid Infill:

Now that we have explored the advantages and disadvantages of gyroid infill, let's delve into its implementation and some tips for achieving the best results:

Software and Slicer Settings:
To utilize gyroid infill effectively, ensure that your 3D printing software and slicer support this infill pattern. Most popular slicing software, such as Cura, Simplify3D, or BigRep BLADE, provide gyroid infill as an option. Select the gyroid infill pattern and adjust the infill density according to your requirements. Experimenting with different densities can help find the optimal balance between strength and material usage.
Print Orientation:
Consider the orientation of your print when using gyroid infill. The orientation can affect the strength and overall performance of the 3D printed object. For parts that require enhanced strength in a specific direction, orient the print accordingly. Testing and analyzing the load-bearing capabilities in different orientations can help optimize the performance of your prints.
Infill Density:
The density of gyroid infill determines the amount of material used and impacts the structural integrity of the print. Higher infill densities result in stronger prints but require more material. Conversely, lower infill densities reduce material usage but may sacrifice some strength. Finding the right balance between infill density and material efficiency is crucial. Consider the specific requirements of your print to determine the optimal infill density.
Experiment and Iterate:
As with any 3D printing technique, it is essential to experiment, iterate, and test your prints. Adjust the infill density, print orientation, and other parameters to find the optimal settings for your specific application. This iterative approach will help you fine-tune your prints and achieve the desired balance between strength, weight reduction, and aesthetics.

Conclusion:

Gyroid infill offers a multitude of advantages in 3D printing, including

enhanced strength,
significant weight reduction,
material efficiency,
improved print quality,
and versatile applications.

Its interlocking structure provides superior structural integrity, making it ideal for functional prototypes, mechanical components, and lightweight structures.

To leverage gyroid infill effectively, ensure that your software and slicer support this infill pattern, and adjust the infill density and print orientation to meet your specific requirements.

Experimentation, testing, and iteration are key to achieving optimal results with gyroid infill.

Utilizing gyroid infill can significantly enhance the strength, efficiency, and appearance of your 3D printed objects. Regardless of whether you are a hobbyist, engineer, or designer, incorporating gyroid infill in your 3D printing process can unlock new opportunities and enable innovative applications.

Want to Learn More About Gyroid Infill?

Explore the innovative use of gyroid structures in wind turbine manufacturing and biomedical applications with expert Jörg Alber from TU Berlin. Don't miss out, watch the webinar now:

THE 3D-PRINTED GYROID: IMPROVING STRUCTURALLY DEMANDING APPLICATIONS

About the author:

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.

Students Bring “Breathing” Audi Car Seat to Life with 3D Printing

April 29, 2024July 19, 2023

Audi Car Seat by Braunschweig students "Concept Breathe"

Responsive car seat enabled by large-format 3D printing showcases innovation potential for additive manufacturing in the automotive space.

While the focus is often on engine power and exterior design when talking about cars, there is another automotive feature ripe for innovation. The car seat, which functions as the interface between driver and vehicle, is one of the most important elements of a car and must offer ergonomic support, safety features, and comfort.

In recent years, there has been a growing focus on how to reinvent and improve automotive seating using new design concepts and advanced manufacturing, such as 3D printing. One such project, entitled “Concept Breathe”, was the result of a collaboration between students at the Braunschweig University of Art, German automotive manufacturer Audi, and large-format 3D printing specialist BigRep.

A Multi-Partner Effort

Concept Breathe, which culminated in the creation of a full-sized “breathable” car seat, was born out of an exploration into the car of the future. The Braunschweig design students, under the supervision of Dr. Manuel Kretzer, a professor of Material and Technology, and Audi’s development/innovation unit led by Mike Herbig, were inspired by the idea that the car of the future could have a greater connection to the driver. As they say: “What if it were to become a partner that reacts and responds to our actions, an organism, a friend, that lives and breathes?”

Interestingly, Audi had already started pursuing this idea with the development of Klara, a “sensitive Audi A1” in 2017. This concept study aimed to foster greater empathy between automobile and driver by creating a sensitive car that appears to breathe. The breathing effect was the result of 39 electric motors installed under the car’s metalwork and several sensors that would enable Klara to take breaths and react to its surroundings.

The Concept Breathe car seat project, undertaken in the spring of 2017, was an extension of the experimental Klara initiative that sought to combine different technologies and design principles to create a more human car seat that could dynamically move along with the driver.

“What if the seat were to become a partner that reacts and responds to our actions, an organism, a friend, that lives and breathes?”

Braunschweig student designs for Audi seat "Concept Breathe"

Design and Form studies in side view by Maximilian Dauscha

Conceiving of ‘Concept Breathe’

The seating project was spearheaded by a group of 10 bachelor students at the Braunschweig University of Art as part of their Digital Crafting module. The courses in this module are specifically aimed at developing “an experimental understanding of emerging design opportunities” by leveraging innovative algorithmic and parametric design principles, as well as digital manufacturing technologies, such as 3D printing, which bring design concepts to life.

Ultimately, the car seat’s design was inspired by organic shapes and systems and consisted of several active components integrated into a lightweight frame. Due to the final design’s complex geometry—which was the result of several parametrically designed iterations—the student team and their partners decided to 3D print the 1:1 seat prototype. BigRep, known for its large-scale 3D printers, was more than up to the task.

The seat structure was 3D printed using the BigRep ONE machine, which has a large build volume of up to one cubic meter, and BigRep’s PRO HT filament, an easy-to-print biopolymer with enhanced temperature resistance compared to traditional PLA. The printing process took nearly 10 days to complete, which at the time marked BigRep’s longest print.

Onto the 3D printed frame were attached 38 customized active components, which created a haptic and visual breathing effect, along with a range of specially designed cushions made from a high-performance textile for optimized comfort and support. As the design team put it: the active components (seen in red) “are designed to increase the seat's ability to respond to changing driving conditions but especially to enhance the user's identification with the animate object through motions of breathing.”

Audi Breathe Chair 3D print on BigRep ONE

Paving the Way for Innovation

BigRep’s 3D printing technology was vital to the realization of the project. Not only was the company’s large-format 3D printer equipped to handle the scale of the full-sized car seat structure (reducing the need for post-printing assembly), it was also able to reproduce the product’s complex organic shape. Moreover, 3D printing offered the project partners a cost-accessible way to directly create a large prototype without having to invest in tooling or turn to complex supply chains.

In the same way that large-format 3D printing was critical to bringing this concept design to life, the technology is now being used across the automotive industry to explore new design ideas and bring new innovative solutions to market, from rapid prototypes to end-use parts. In automotive seating applications in particular, there have been a number of projects that leverage the technology’s ability to create complex designs optimized for performance and comfort, as well as customized products at scale.

Similarly, German automaker Porsche recently launched a 3D printed bodyform full-bucket seat that integrates customizable 3D printed lattices for superior support and breathability. Much like Concept Breathe, the 3D printed seat emphasizes the human and technology connection to generate an enhanced driving experience, particularly for high-performance vehicles.

3D Printed Audi Car Seat by Braunschweig Students

3D Printing is the Future of Automotive

Ultimately, the Concept Breathe project would not have been possible without additive manufacturing, particularly BigRep’s large-format 3D printing. The technology proved to be essential for rapidly and cost-effectively bringing an innovative idea to life.

For the broader automotive industry, the ability to 3D print large structures and products in a single piece has huge benefits. For one, it allows for design consolidation, allowing for large structures to be printed in one go, minimizing assembly and post-processing times. This has significant time and cost impacts whether users are printing a design concept, a functional prototype, or an end-use part.

The technology also enables product designers to create previously impossible designs, opening up limitless opportunities for innovation. With it, forward-thinking individuals and teams (such as the Braunschweig design students and their partners at Audi and BigRep) can really dive into new ideas and transform them into something real, something that can shape the future.

To learn more about how 3D printing helped bring the Concept Breathe article to life, check out the following video and the original coverage of the project.

Interested in how the BigRep ONE can unlock your innovation? Learn more about large-scale printing here.

How to Choose Which Features You Need on the Modular BigRep ONE 3D Printer

June 2, 2023June 2, 2023

How to Choose Which Features You Need on a Modular BigRep ONE

The BigRep ONE is a modular large-format FFF 3D printer designed to produce high-quality, long-lasting parts while saving you time and money. With a massive build volume of one cubic meter and versatile modular feature configurations, it’s perfect for a wide range of applications, including prototypes, furniture design, creative exhibitions, automotive components, tooling, and more.

The latest version, the BigRep ONE.4 can be configured with various modes and add-ons. Customize the specific large-format 3D printer for your current needs, while you also have the possibility to upgrade as those needs change in the future. It’s important to understand the BigRep ONE’s standard features and capabilities as a modular 3D printer, so you can adjust the ONE to meet your specific Additive Manufacturing needs.

Which Features Does the BigRep ONE.4 Already Have?

The newest iteration of the BigRep ONE has an array of fantastic features that give you full control over your prints.

Massive Print Volume

The ONE.4’s massive one cubic meter build volume firmly establishes it as one of the biggest 3D printers in FFF manufacturing, giving you the ability to unleash your potential in a way that smaller printers simply cannot achieve.

Enclosed Safe Frame

The ONE.4 has a plexiglass enclosure, perfect for monitoring print progress as well as showing your work to any potential visitors. It also provides CE-compliant operator protection: if you open the enclosure mid-print, the machine will stop running. The enclosure reduces temperature fluctuation within the build volume, which is important for maintaining quality and consistency, especially during longer prints.

PEX Fiber-Ready Extruder

Featuring 0.6mm, 1.0mm, or 2.0mm nozzles, the fiber-ready Power Extruders (PEX) provide versatile solutions from maximum detail to high-flow 3D printing. While producing amazing results with BigRep materials including biopolymers, water-soluble support, engineering-grade materials, and fiber–reinforced filaments, the fiber-ready Power Extruder is open for printing with 3rd party materials.

BigRep Fiber-Ready PEX (Power Extruders)

Semi-Automated Print Bed

The 1M2 print bed is covered with polyimide foil to ensure that your print stays fixed to the print bed, with additional adhesion possible with glue such as Magigoo. The ONE.4 features semi-automatic print bed calibration to ensure proper extrusion and adhesion of the first layers of your print. For fully automatic calibration and even more control, however, it’s worth checking out the BigRep PRO.

Out-of-Filament Sensor

The BigRep ONE’s out-of-filament sensor pauses all prints when you are out of filament, essential for large prints that may use up multiple spools. Simply replace the filament and continue your print.

Intuitive User Interface

For full optimization and calibration of your print, the BigRep ONE is equipped with an intuitive user interface. It helps you remotely load gcodes onto the system, or manually with a USB stick, calibrate the print bed, stop and start operations, and monitor systems in conjunction with BigRep CONNECT.

Filament Enclosure

The filament enclosure has been designed to fit all standard spool sizes, including two spools up to 8kgs. This allows for longer, more continuous printing time.

Standard Camera

For extra-large prints that can take days or even weeks, it’s important to be able to monitor your prints remotely from your computer, tablet, or mobile device. The ONE.4 comes with a webcam attached to your printer, allowing for worry-free prints. The camera also allows you to make time-lapse videos, which can be useful for boosting your marketing outreach.

Which Configuration Works for Me?

The ONE.4 is customizable to meet your specific needs, which begins with the extruder combination you choose.

SINGLE MODE

Single Mode is the most affordable option, a basic configuration with a single Power Extruder and a 1mm nozzle. This option is great for prototyping and testing large-scale prints on a lower budget, however, water-soluble support isn't possible in Single Mode.

DUAL MODE

Our most popular configuration is Dual Mode, which allows for dual extrusion. This is perfect for producing complex geometries when you need water-soluble support for easy removal after printing. Some customers prefer to keep different nozzle sizes on either PEX to avoid swapping out nozzles for different prints. Another advantage of dual extruders is having two different primary materials readily loaded for fast switching between filaments.

TWIN MODE

Twin mode is perfect when you want multiple prints of the same geometry, speeding up your output by 100% and doubling your production. As both extruders work simultaneously, you can print two versions at once, cutting costs and reducing time-to-part by 50%. With Twin Mode, each extruder can print within one-half of the build volume, so Dual or Single Mode is required for larger prints needing build volumes over 0.5m2.

Which Additional Add-Ons Are Available?

The BigRep ONE is a modular printer, so you can choose features to optimize your 3D printer based on your specific needs. Here are the useful add-ons that you may want to consider:

Keep-Dry Add-On

If you want to improve quality and make the highest-quality prints possible, then it’s important to keep your materials dry, particularly engineering-grade and hygroscopic filaments. The keep-dry box protects filaments from environmental moisture and dust, which is especially important for materials such as TPU, BVOH, and HI-TEMP.

Connected Camera

For additional peace of mind, the ONE.4 can be equipped with a USB camera and integrated into BigRep CONNECT, a new monitoring and analytics software that lets you keep track of prints, job queues, material usage, and more... plus, BigRep CONNECT is free.

Dual Mode Add-On

If you already have Single Mode, you can upgrade to as your needs change to print with two extruders instead of one. This is also necessary to install first if you want to print in twin mode.

Twin Mode Add-On

If you have Dual Mode already enabled, the twin kit add-on allows you to upgrade to twin mode as well.

Custom Color

The BigRep ONE is easily identifiable with its trademark orange corners, but you can rebrand your ONE.4 with the custom color add-on to match your company's color scheme or corporate identity.

Three Different Personalities of the BigRep ONE

In the race for 3D printing success, knowledge is half the battle. Understanding the full capabilities of the ONE should give you an indication of which features you need to get the most out of your 3D printer. It’s always worth considering exactly what your aims are before tailoring the ONE to meet those desires. To give you an indication, we have three potential combinations you could work with:

The Sprinter

As the name suggests, the Sprinter is all about speed and is great for ramping up output of batch production. Once design and calibration, material usage, and bed-leveling are set, the Sprinter works quickly and efficiently to simultaneously produce two identical parts. A Sprinter setup could include the Twin Mode extruder configuration with a 1.0mm nozzle, doubling production capabilities, and a CONNECT camera to monitor 3D prints over long periods.

The Essentials

When you want a large-format 3D printer at a smaller price, you may want only the Essentials. Opt for a no-thrills, all-business Single Mode ONE.4 configuration perfect for rapid testing and production. The Essentials includes a single fiber-ready Power Extruder with a 1.0mm nozzle. Perfect for beginners, it's a robust solution at minimal cost.

The Perfectionist

The Perfectionist is a ONE.4 configuration suited for applications requiring the best quality using materials that deliver. For complex geometries, Dual Mode is recommended to enable the ONE.4 to print water-soluble support, like BigRep BVOH, together with a range of compatible materials. To keep sensitive materials in optimal condition, add on the Keep-Dry Box to protect filaments from environmental moisture and dust. For maximum detail, this Perfectionist approach utilizes a 0.6mm nozzle for finer-quality prints and lower layer heights.

Don’t Limit Yourself

In the 3D printing world, there are no limitations to what you are capable of. With the BigRep ONE, you are given the opportunity to create a 3D printer completely in line with what you want to achieve.

As your 3D printing needs evolve, simply upgrade your ONE with additional features to grow along with you. If you need a custom solution for your needs, please feel free to contact our team today.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

Explore the ONE

About the author:

Lindsay Lawson

Head of Product Marketing

SFM Technology Create the First Helicopter Blade Restraint Cradle With 3D Printing Technology

March 24, 2023March 24, 2023

When tasked with creating restraint cradles that allow helicopters to load safely, SFM Technology turned directly to the BigRep PRO.

Rough seas not only make smooth sailors, they also make smooth engineers who can find innovative solutions to choppy conditions. This is especially true when it comes to aviation, as helicopters are frequently tasked with embarking onto ships during all different types of weather conditions.

Once helicopter flying operations have ceased, they will either stay on the flight deck or be stowed in the ship’s hanger. They use an automatic folding system, folding in their blades like a bumblebee. The issue of stabilization remains a key priority when it comes to the smoothest embarkation possible. This is achieved by using a main rotor blade restraint cradle.

As Gary Wilson, head of Technical Sales at SFM's AeroAdditive division tells us: "When a helicopter is on board a ship, it can fold its helicopter blades back. But at sea it's still windy, and the blades can flap. These blades must be restrained so flapping doesn't occur."

Aerospace and defense giant Leonardo - tasked by the Ministry of Defence to provide AgustaWestland AW101s for the Royal Navy - found that their pre-existing main rotor blade restraint cradles were not living up to their standard. They turned to SFM Technology's AeroAdditive department for the solution, resulting in the first 3D-printed main rotor blade restraint cradle, measuring 900 x 230 x 160mm. Gary Wilson explains how they created the cradle and why he believes this is just the start for additive manufacturing within the aerospace industry.

The Blade Restraint Cradle, Printed on a BigRep PRO

3D PRINTING PROVIDES THE SOLUTION

As a solution had to be found very quickly, SFM relied on the speed of innovation possible with additive manufacturing.

"We had to look at many aspects of 3D printing, including cost, efficiency, and of course, size. Eventually, we looked at the BigRep PRO as we had to look at a production 3D printer. The machine is used as a production machine, so every rotor blade restraint cradle goes to the end customer."

3D PRINTING MORE VERSATILE THAN TRADITIONAL METHODS

In the aerospace industry, lightweight yet strong parts are essential. After stress-testing their 3D printed parts, SFM Technology found that they performed better than original, non-printed parts. By using Hi-Temp CF – a carbon fiber reinforced material with versatile, high-strength properties – the blades are extremely durable and weather resistant.

The benefits have been manifold.

“To date, we have printed 30 cradles, consisting of 60 halves, since January. If we were to do that in a traditional way, we would have done about a quarter of that. So, you can see that 3D printing is far quicker, as we don’t have any adjustments to make, or if we do, they’re very minor and can be quickly overcome. And the material is just as strong.”

THE ADVANTAGES OF HI-TEMP CF

Choosing the right material was crucial in SFM’s choice.

“We carried out many tests to establish which was the most suitable material within the budget given. Having looked at the data sheets, we felt that BigRep's HI-TEMP had a slight advantage over the other BigRep materials.”

Once they remove the support material, sandpaper is used to smooth the surface. Bushes - a type of fixed or removable cylindrical tube - are inserted in the hinges, before using threaded helicoil inserts for fastening when required. After the cradle is painted to the customer's specification, the remaining hardware is embedded along with a protective foam on the inside of the cradle, preventing it from scratching the blade surface.

The Blade Restraint Cradles in Action

THE START OF 3D PRINTING IN THE AEROSPACE INDUSTRY

With the main rotor blade restraint cradles already in use, Mr. Wilson attests that this experience shows what 3D printing can achieve in the aerospace industry and that it's only a matter of time before additive manufacturing becomes the norm.

"In the aerospace industry, there are many designers nervous about 3D printing. We've demonstrated that 3D printing can be used in the aerospace industry quite comfortably from a strength, repeatability, and quality side. I know for a fact that as the industry moves forward on 3D printing, there will be more and more accessible paths to use."

SFM Technology are using the BigRep PRO as a batch 3D printer, sequencing production and creating improved results across the board. This follows more aerospace designers discovering the benefits of 3D printing and adopting it in due course.

Want to learn more about 3D printing and aerospace. Learn about how 3D printing saved Airbus time and money!

BigRep PRO: Large-Format 3D Printer showcasing advanced technology and high-quality printing capabilities

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.

Explore the PRO

CDM:Studio on Bringing Sharks to Life with The BigRep ONE

April 25, 2024March 17, 2023

A shark model 3D printed on a BigRep 3D printer by CDM:Studio.

Enhancing Traditional Mold-making with Additive Manufacturing

Jason Kongchouy and his Perth-based model-making team CDM:Studio previously brought the past to life with their dinosaur recreations, commissioned for the Western Australian Museum. But there are actually creatures far older than dinosaurs: Sharks! Sharks! is also the name of the latest exhibition from the Australian Museum in Sydney, fully immersing visitors into the world of these 190-million-year-old beasts. They used CDM:Studio thanks to their expertise, experience, and excellence in bringing ancient animals to life.

Traditional clay-making approaches to creating large-scale models can be long and cumbersome. This is where the BigRep ONE provides the perfect solution, allowing for rapid prototyping and printing, significantly reducing production times. We had the chance to talk to Studio Manager and Senior Fabricator at CDM:Studio Jason Kongchouy about his project, the challenges in creating some sharks with minimal references, and the types of materials he used.

Can you start by telling me a little bit about CDM:Studio and what they focus on?

CDM:Studio is our model-making studio based in Perth, Western Australia. We fabricate things and work on creative projects that other people wouldn't necessarily know how to get their head around. We mainly service museums, builders, architects, and designers in a fabrication capacity where we use the BigRep ONE, SLA machines, and a five-axis CNC arm. This is complemented by an extensive skill-set in mold-making and model-making techniques. We're not just a 3D print place, but it's a means to an end to solve these problems for people.

"There was a lot of complicated work that we wouldn't know how to do without the BigRep ONE taking the stress off."

What problem does it solve for you?

A big part of it involves us sculpting digitally using a 3D-modeling program named ZBrush. We're currently doing stuff with more museums at the moment, which is all driven by 3D printing and making those parts one-to-one scale. We use all manner of technology at our disposal to make finished objects because the customer is not buying 3D-printed things. For us, printing is a step in our pipeline. We talked about similar models in the special effects industry before the interview. That used to be all clay and fiberglass, involving months of work. Now it's been replaced with a single 3D modeler and a machine that works 24/7 and takes all that physical strain off us. And in our industry, there is a lot of physical strain, which just exhausts you and creative output can fall as a project goes on. It drops after week six. But with a 3D file, whatever we slice and send to the BigRep, that's exactly what comes out. I think the museum likes that as well. A lot of what we do has to be approved. So we can send the 3D file to the scientists, they can look at it, and they can send it to experts to check it all over the world.

Is it easier to design a shark than a dinosaur? Because sharks, of course, are still around...

Yes, absolutely, but each still have their own challenges to navigate. All the sharks that we made are native to that part of Australia, so they had samples, teeth, and photographs. However, one of the interesting challenges is that no one takes a photo of a shark at a perfect angle so to digitally model them requires a good understanding of anatomy to get the correct proportions. It's hard to get the perfect shape. One of the models in the exhibition is a prehistorical predecessor of sharks called the Helicoprion. We only found a sawtooth mouth fossil, but our current model is where the science is with that creature. There's also a shark that lives deep in the ocean where there are only incredibly limited photos of it in the world, so our reference was a bit scarce, but it was still exciting to realize that as a physical model.

"We're not just a 3D printing service, but a means to an end solving problems for our customers."

How much time do you save using 3D printing instead of traditional clay modeling?

If nothing else was happening, you could print a shark, like the Great White or the Helicoprion, in about six weeks. From a business perspective, you would need a four to five-month window to do the same from a traditional clay-based pipeline. Having the printer frees us up to solve other problems on the projects and lets us focus our model-making skills on parts that are coming off the machine: gluing them together, sanding the surfaces, and covering them in epoxy. There was a lot of complicated work that would take significantly longer without the 3D printer taking the stress off. It helps us streamline and work much more efficiently.

What material do you use to print and why?

For this project, we use BigRep PRO HT. It was recommended to us for its high temperature resistance as it doesn't melt or go soft as easily as PLA. We know that after the exhibition finishes in Sydney, it could tour America or potentially Europe so hopefully, you'll see it one day. These will be traveling across the ocean or be left in super hot places like Arizona, so we needed something very durable like PRO HT. We also reinforced them with epoxy resin and fiberglass because people might touch them in the exhibition.

"These are going to be traveling across the ocean or left in super hot places like Arizona, so we needed something very durable and temperature-resistant like PRO HT."

Any final words about the BigRep ONE and ideas for the future?

For us, it's a really useful tool. I think capability-wise, the ONE is perfect for us. And we look forward to even more interesting projects that the BigRep enables us to service.

Interested in what the BigRep ONE can do for your business? Learn more about large-scale printing here.

Natasha Mathew

Design for Additive Manufacturing: Best Practices for Superior 3D Prints

May 8, 2023February 12, 2023

Design for Additive Manufacturing (DfAM)

Design for Additive Manufacturing:
Best Practices for Superior 3D Prints

The possibilities for designing custom, innovative solutions using 3D printing are endless. While this is undoubtedly true for 3D printing hobbyists who want to create and optimize DIY projects, the advantages to Additive Manufacturing (AM) grow exponentially at an industrial scale, especially when you own a large-format BigRep printer.

Aside from freedom of design, 3D printers offer the added benefits of low-cost customization, agile iteration, faster time-to-market, reduced material waste, and a way to avoid complicated logistics and supply chains. However, not all designs are suited for Additive Manufacturing. Having the right knowledge is crucial to get the most out of your printer, especially regarding the earliest design and conceptualization stages. This is where Design for Additive Manufacturing (DfAM) can make or break the success of your project.

What is Design for Additive Manufacturing?

Additive Manufacturing (AM) is the process of creating an object by building it up one layer at a time. It is the opposite of subtractive manufacturing, where an object is produced by cutting away at a solid block of material until the final product is complete, such as CNC machining. While the terms are often used interchangeably, the most common form of Additive Manufacturing is 3D printing. DfAM is a method of designing parts specifically for Additive Manufacturing, which have unique requirements different from other common manufacturing processes such as injection molding or casting. The critical difference between DfAM and traditional design is that DfAM principles guide designers to take full advantage of the unique capabilities of 3D printing while avoiding some of its limitations with smart solutions.

This guide will explain some factors that make a design well-suited for 3D printing, plus it will introduce DfAM principles so you can maximize your 3D printing results.

Why DfAM Matters

Understanding DfAM is essential to ensure successful, repeatable, and scalable results that maximize 3D printing capabilities. What will you get from following DfAM guidelines?

Reduced material and part costs: By implementing DfAM principles, unnecessary supports are avoided, reducing materials and lowering the cost to print. By using generative design software and AI, parts can be designed to minimize material usage while easily still meeting all of the necessary part requirements.
Faster print times: Large-scale 3D prints may run for days or even weeks! However, when components are optimized for Additive Manufacturing, you can implement the most effective printing plan, ensuring the shortest print time that is possible.
Increased scalability: By designing with DfAM principles, designs can be printed on various printers and scaled up or down without requiring significant adjustment. 3D printers can also produce sequential batches of prints or, in some cases, parallel prints that drastically speed up the time required to produce each part.
Improved part strength: With Design for Additive Manufacturing principles, you can increase the strength of your 3D print, plus you can alter factors like part weight, flexibility, and more. CAD software with generative design functions uses algorithms to produce geometries that meet strength and performance requirements.

DfAM Best Practices

Design for Additive Manufacturing principles result in many overall benefits, but some specific design choices will be influenced by the type of 3D printing technology used. However, DfAM best practices will help you reduce material use and printing time, consolidate parts, and optimize topology and performance, no matter what 3D printing technology is implemented.

1. DfAM Depends on Your Specific 3D Printer

Before you start designing for 3D printing, you must understand the different types of processes available. The most popular 3D printing processes include FFF (also commonly referred to as the trademarked term, FDM), SLA, and SLS.

FFF (fused filament fabrication) 3D printing consists of layers of melted plastic deposited onto a build platform. The plastic, in the form of a spooled filament, is fed through a heated nozzle that softens the material and extrudes it in a thin stream. The printer then lays down the melted plastic according to the design specifications of the printed model. Once each layer is complete, in the case of large-format FFF 3D printers, the extruder moves up in the Z axis exactly one layer height and another layer is deposited on top. In the case of some smaller desktop printers, the build platform lowers by the amount of one layer height to print the next layer. This process continues until the model is complete. Desktop FFF 3D printers are relatively simple and inexpensive, making them one of the most popular types of 3D printers among hobbyists and home users. However, large-format and specialized FFF machines can produce high-quality results, making them a viable option for professional and industrial applications. Any FFF 3D printer will require support structures for parts with overhang angles and bridging distances beyond limits. Depending on the model of FFF 3D printer, minimum wall thickness, layer heights, and other settings will vary. FFF 3D printers can print with a variety of materials, but virtually all filaments are some type of polymer which may also include fiber, metal, wood, or other additives. Some FFF printers can use water-soluble materials for printing support structures, which can then be dissolved in water for easy removal.
SLA (stereolithography) uses ultraviolet (UV) light to cure and solidify photosensitive resin layers one at a time. As each layer is printed, the vat of resin also containing the print in progress lowers by one layer thickness. SLA prints may require some support structures, which are slightly different from FFF supports and are not available in water-soluble materials. SLA prints typically require cleaning after printing to remove any residual uncured resin otherwise, the print would be sticky and harmful to human skin.
SLS (selective laser sintering) uses a laser to fuse powder materials, layer by layer, to create a 3D object. After each layer is printed, the powder bed is lowered by one layer thickness so another layer can be sintered on top. SLS prints do not require support structures because the print is surrounded by unsintered powder during the printing process. Finished SLS prints typically require cleaning, sometimes with specialized machines, to remove loose powder from the 3D printed part.

2. Reduce Material Usage and Printing Time

When designing a 3D model for Additive Manufacturing, it is crucial to consider the amount of material required and the time it will take to produce the finished product. Reducing material usage can reduce overall production costs and speed up the manufacturing process. You can minimize material by:

Reducing the surface details in the model: Most 3D printing software has specific tools for reducing the surface details in the 3D model.
Tweak the slicer settings: You can reduce the infill percentage, the number of walls, and more.
Reorient the part: Reduce printing time, material usage, and support requirements with optimized part orientation.

3. Part Consolidation

One benefit to 3D printing is that parts that would traditionally need to be produced separately and later assembled may be 3D printed as a single, consolidated part. By doing this you can reduce printing time, increase production speed, reduce assembly time, and enhance part strength. As an added bonus, part consolidation may only be possible with 3D-printed parts, and by utilizing DfAM guidelines you may be maximizing the benefits of Additive Manufacturing. Part consolidation benefits include:

Reducing the overall number of parts that need to be manufactured as multiple parts are combined together
Reducing the amount of time needed to manufacture each individual part
Reducing the amount of waste material generated during the manufacturing process
Improving the mechanical properties of the final part by reducing internal stresses

4. Topology Optimization

Topology optimization principles aim to use the minimum amount of material that can meet given performance requirements while minimizing the weight of the component. First, you must specify the mechanical performance requirements (such as stiffness or strength) and design constraints (such as maximum allowable stress or displacement). Some CAD software can simulate how your part will respond under different loads. Based on the results of the analysis, you can then automatically adjust various design parameters until an optimal solution is found.

Topology optimization can improve a component's strength, stiffness, or weight as well as reduce manufacturing costs. It is often used with finite element analysis (FEA) to assess the effects of design changes on the component's performance. The results can then be used to create a new design that is more efficient and effective.

Design for Additive Manufacturing Guidelines

Like any other manufacturing process, there are best practices to produce quality 3D-printed parts.

1. Minimal Feature Size

Minimal feature size refers to an object’s minimum width or height that a 3D printer can accurately print. Sharp corners, holes, protruding text, and cutouts are the types of features where a minimum size can be critical for success. No matter on which axis the feature is oriented, it is usually constrained by the 3D printing technology used, as well as the specific hardware (e.g. nozzle size) or machine accuracy.

If your 3D-printed part requires holes, the minimum diameter will be dependent on different factors depending on the 3D printing technology. With SLS, for example, the holes must typically have a diameter over 1.5 mm to prevent powder from getting stuck in the holes. With FFF 3D printing, the minimum hole diameter is mainly dependent on nozzle size and layer height.

One DfAM recommendation is that all sharp corners should be chamfered or filleted to reduce stress. Applying chamfer and rounding the sharp edges ensures that shrinking forces concentrating on one specific point in the design are dispersed.

2. Wall Thickness and Layer Height

Wall thickness refers to the thickness of the printed object's walls, which are made of perimeters that are sometimes called the wall line count. The absolute minimum wall thickness is a single extruded line (a wall line count of 1) that is dependent on nozzle size: it must not be smaller than the nozzle diameter and usually slightly larger than the nozzle diameter, typically by a factor of 1.2. Additional wall lines such as inner walls, as well as infill, may be printed thinner than the nozzle diameter but is typically a minimum of 60% of the nozzle diameter.

A secondary factor determining minimum wall thickness is the overall geometry and intended use of the 3D print. If it is a functional object subject to stress or force, it is important to use thicker walls with a higher wall line count. If the object is a prototype for design iterations or fit checks, then thinner walls with fewer lines may suffice. The thicker the walls, the longer it will take to print the object and the overall part weight will increase.

Layer height, which is the thickness of each layer measured in the Z axis, will also factor into your DfAM choices. Although layer height settings are determined during the slicing, your design can be informed by which settings you plan to use. For example, a minimum feature size is dependent on layer height, so you should avoid designing features that your 3D printer cannot produce.

Layer height is dependent on the nozzle diameter: the height must be less than the nozzle diameter, typically a factor ranging from 0.3 to 0.6. The higher the layer height, the faster the print and the rougher the appearance of the layer structure on the surface. Part strength is somewhat impacted by interlayer bonding and the strength is slightly increased with higher layer heights. Typically, lower layer heights are used for finer, more precise prints with smoother surfaces, while higher layer heights are beneficial for faster printing when surface smoothness is not important or can be managed with post-processing.

Desgign for Additive Manufacturing: Layer Height

3. Support Structures

While not technically part of the design process, support structures may be avoided by following DfAM principles, thereby reducing printing time and material usage, and improving surface quality.

Support structures are temporary structures that help to reinforce 3D objects, prevent them from collapsing during the printing process, and improve their overall strength and durability. 3D models with overhangs or elements with a small contact area with the build plate require support structures during 3D printing. Parts with delicate features or low-density areas may need support structures to prevent them from being damaged during 3D printing. However, each 3D printer and material has its own threshold for requiring supports; a rule of thumb is that parts with a vertical angle of 50 degrees or less don't require it.

Support structures are designed to be removed after the printing process. Breakable supports can be printed with the same material as the print and are manually removed when the print is completed. Another solution are supports, printed in a water-soluble material, that can be dissolved after printing. These are usually easier to remove and result in better surface quality. By following DfAM guidelines for overhangs and bridging (as noted below), you can reduce or entirely avoid the need to print support structures.

4. Overhangs

An overhang is any geometrical shape extending beyond the previous layer without any support structure. If an overhang is too steep, typically over 50°, it will sag or collapse without using a support structure.

When designing for Additive Manufacturing, you can adjust these angles to keep within maximum overhang angles, thereby avoiding overhangs that require support. The benefit of this is threefold: the printed surface will look better, the print will be faster, and it will require less material usage. With the BigRep BLADE slicer, the support structures can be created automatically based on material and machine-specific profiles. To experiment with higher maximum overhang angles, you can change this setting and reduce the automatically generated supports. The choice of material will also affect the maximum overhang angle achievable without support. If your project allows, you can choose a material that tolerates higher overhang angles to avoid printed supports.

5. Bridging

Bridging occurs when material is printed in mid-air spanning two or more otherwise disconnected segments without a printed layer below. To successfully bridge, the material must be able to keep its weight as well as the weight of the model itself. The maximum length of a bridge will depend on the material and the 3D printer. Beyond that limit, the bridge will sag unless support structures are printed below. By choosing a material with better bridging properties, you may be able to avoid printed supports without altering your design.

As seen in the image below, the quality of a bridge degrades the longer it is. In other words, past a certain (material, machine, and geometry dependent) threshold, the bridge will sag. The image below shows a test print demonstrating various bridge lengths printed with a BigRep ONE using PLA filament. Here we see that the bridge quality begins to suffer when longer than 50mm. Keep in mind that this test print is a simplification of a real-world 3D printing application, so your 3D print will likely require shorter bridges or support structures when compared to this test print.

Bridging - Design for Additive Manufacturing

Bridging front view - Design for Additive Manufacturing

6. Orientation

Part orientation is a setting determined during slicing, but your part design can be influenced and improved with this setting in mind during the design stage. By changing the orientation of the part within the printer's build volume, you can increase part strength, reduce printing time, improve surface quality, and avoid 3D-printed support structures. For stronger parts, the print should be oriented so that the printed layers are perpendicular to the direction of the force that will be applied to the part. This is because the inter-layer bond, where each layer touches the next, is the weakest part of the print. By orienting the layers perpendicular to the forces the printed part must withstand, it will be more resistant to breaking.

Part orientation can affect the overall print time by reducing travel moves (when the print head moves the extruder to a new location without printing) and by reducing the need for printed supports.

The surface quality is negatively affected by part orientation in two ways: support structures and the staircase effect. Support structures can impact the surface quality of a 3D print which may appear rougher, more irregular, and may be damaged during the process of support removal. The staircase effect occurs when the ridges created by the printed layers are more pronounced on a 3D print, as seen on the image to the right. This can be reduced in a few ways to make the print surface appear smoother. First, the layer height can be reduced, but this will increase printing time. Secondly, the part can be oriented so that the layers are built up perpendicular to the surface of the 3D print. If it is important that a particular surface is smoother, the print should be oriented so that surface is as vertical (in relation to the print bed) as possible.

7. Tolerances

In Additive Manufacturing, tolerance measures how much deviation is acceptable or expected from the original 3D model. It is, in other words, how closely the 3D print measures up to the digital model. It is essential to consider tolerance when designing parts for 3D printing, as the build process can introduce inaccuracies.

Support structures can affect tolerance if they leave an overly rough or distorted print surface after the supports have been removed. Understanding tolerances is essential because they determine how well a part will fit and function as intended. For example, a loose tolerance may cause the 3D-printed part to be loose and wobble if fitted within another structure while a tight tolerance may cause a part to be difficult to assemble or create excessive wear.

The achievable tolerances of a 3D print are dependent on the accuracy of the 3D printer itself, its components, and the material used. Accurate tolerances can be negatively impacted by the 3D printer when it is not properly calibrated or vibrates too much during printing. Tolerances are also determined by nozzle diameter and layer height. A 0.6 mm nozzle will be able to achieve smaller tolerances than a 2 mm nozzle. Higher layer heights will give a rougher surface resolution, which also affects the achievable tolerance of the 3D-printed part.

8. Infill

Infill is a 3D-printed interior structure, typically a lattice pattern, that fills the interior cavity of a 3D print. The type and density of infill are determined in the slicing, but it can be useful to know what infill is needed when initially designing your part.

Infill serves two functions: it increases the strength of the part and is necessary to support the top layers of certain geometries. The infill can be a variety of patterns like a grid, triangle, or gyroid, and its density is determined by the slicing settings ranging from 0-100% of empty versus solid space. With 0% infill, the part will be lighter and print faster, but the part will be weaker. It is virtually never necessary to print with 100% infill, as the increased part-strengthening effect of infill is typically negligible above a certain percentage. The second function of infill, to support top layers, is only a factor depending on the part geometry. If the top area is smaller than the distance that can be achieved by bridging, then no infill may be required unless part strength is a factor. In practice, most 3D prints require infill to support the top layers and the infill density required for adequate top layers depends on the number of top layers, the machine's capabilities, and the material used. If a 3D print only has one top layer, the space between the printed infill walls may sag, but with additional layers, the final top layer may compensate and appear as intended.

The correct settings depend on your project requirements. For example, if you are 3D printing an object that does not need to be strong, you can use a lower infill setting to save time. When designing for Additive Manufacturing, the infill should be as strong as possible while using the least amount of material. This helps to reduce the weight of the object and the overall cost of printing.

If your design constraints allow, you can change the geometry of your part to minimize the need for infill or avoid it altogether. This can result in a faster 3D print, better surface quality, and reduced material usage.

Testing and Validating Your Design

After following DAM principles, the success of your design can be evaluated before or after printing.

DfAM Software

Design for Manufacturing software, like DFM Pro, verifies if design rules for Additive Manufacturing are followed. The software takes the 3D part, identifies possible manufacturing issues, and suggests fixes. Automatic fixes can be applied.

FEA Software

FEA (Finite Element Analysis) software can be used to analyze the mechanical properties of your design before printing. You can alter your design using DfAM guidelines, AI, and/or dedicated software to improve the parameters within your digital 3D model.

Test Printing

Assuming that your 3D printer is calibrated and functioning properly, you can 3D print your part to evaluate the success of your design and iterate as needed. The ability to easily print tests, evaluate, redesign, and reprint is one of the great benefits of Additive Manufacturing.

Limitations of Design for Additive Manufacturing

Although designing for Additive Manufacturing has many benefits, it still has some limitations to what a specific 3D printer, material, or 3D-printing application can achieve. While DfAM guidelines can result in better 3D prints, they can not overcome inherent design flaws that may affect the overall functionality of a part.

One limitation of DfAM is human error. On one hand, expertise can greatly benefit the quality and outcome, but without the use of algorithms or AI, there is a limit to what experience can achieve, particularly in novel situations. The need to iterate designs and reprint can increase costs and delay timelines. When the time for design iteration is limited, analysis software (like DFM or FEA) and hardware (3D scanner) can reduce the likelihood of mistakes, however, these may require additional tools and software competence.

Some critics of DfAM suggest that stringent design rules result in less original or innovative designs, becoming more homogeneous in style. Others counter that the use of Additive Manufacturing opens up a world of design possibilities not achievable with other production methods.

Conclusion

The DfAM approach is a powerful set of design tools that can improve the end result of additive manufactured products and parts. DfAM is essential for efficiency and consistency when designing models for 3D printing and is particularly essential for industrial 3D printing, improving the performance of products by making them lighter and more robust.

In many cases, DfAM can also benefit aesthetic choices to result in beautiful, quality 3D prints. DfAM is an evolving set of rules and best practices, which can be modified for specific design tasks and as 3D printing technology evolves.

Want to know more? Watch this webinar to learn about industrial design for Additive Manufacturing.

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

Explore the PRO

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

Explore the PRO

About the author:

Dominik Stürzer

Head of Growth Marketing

Carbon Fiber 3D Printing: Everything You Need To Know

April 18, 2024January 24, 2023

Carbon Fiber 3D Printing: How to 3D Print Strong Parts

Adding carbon fiber (CF) to filaments improves both strength and stiffness. The added strength and increased stiffness provided by the addition of CF leads to a better strength-to-weight ratio, achieving lighter, stronger parts with less printing time.

Read on below to see how carbon fiber can benefit your manufacturing business and learn about the unique properties of CF filaments.

What are Carbon Fiber Filaments?

Carbon fiber-reinforced plastics (CFRP) bring together the qualities and performance properties of carbon fiber with the polymer material they are reinforcing. Printability and ease of use of a standard thermoplastic like PLA, ABS, or PET gains superior performance properties by including carbon fiber content.

Chopped fibers are mostly used for industrial production and also 3D printing. These carbon fibers come as a "filler" material in thermoplastic materials for injection molding or as carbon fiber filaments to use in 3D printers. They can be processed like any other thermoplastic material. But they have extra requirements which will be explained later on.

FFF (extrusion-based) 3D printing uses chopped carbon fibers. These small fibers are then mixed into a standard thermoplastic as a reinforcing material.

Why do you need Carbon Fiber 3D Printing?

Industrial environments often demand specific mechanical properties and finely tuned precision. Fortunately, by bringing together the capabilities of a high-strength material and the many advantages of additive manufacturing, carbon fiber 3D printing offers exceptional dimensional stability in strong, stiff parts with a fine surface finish and a high heat deflection temperature - ideal for functional, high-performance applications.

With 3D printing moving ever deeper into end-use production, the ability to manufacture both parts and tooling using carbon fiber filaments is increasing in demand.

Whether using these materials in molds, jigs, fixtures, tooling or high-performance race cars, specialty aerospace equipment, or professional cycling equipment, carbon fiber 3D printer filament enables you to create the high-strength parts you need. Of course, as a relatively new offering in the manufacturing industry, carbon fiber 3D printing may have many pros, but it's also worth being aware of the printing requirements before you get started.

Carbon Fiber Filament used in 3D printing

Close-up of carbon fiber 3D printed part in manufacturing process

This pattern was printed in BigRep Hi-Temp CF and is used to create drones parts made of carbon fiber prepreg.

Pros of Carbon Fiber 3D Printing

The advantages of carbon fiber 3D printing come down to their performance properties:

High Strength

Perhaps the most-touted property of carbon fiber 3D printer filament, high strength is key to its performance — and desirability as a 3D printing material. Carbon fiber offers a strength-to-weight ratio that enables high performance with low density.

Dimensional Stability

By lessening the tendency for part shrinkage, carbon fiber's high strength and stiffness contribute to its excellent dimensional stability upon usage, essential for parts that require precise dimensions and tight tolerances.

Light Weight

Hand-in-hand with its strength is the light weight of a carbon fiber 3D printer filament. Light weights are a key advantage of 3D printing in general, and using carbon fiber materials enables that weight reduction without a loss of performance-grade strength.

High Heat Deflection Temperature

Compared to standard 3D printing materials like PLA, ABS, and PETG, carbon fiber filaments can withstand significantly higher temperatures. Carbon fiber composite materials — such as BigRep's PA12 CF — enhance the heat deflection temperature of the base material for better performance at elevated temperatures.

LESS POST-PROCESSING REQUIRED

CF filaments make layer lines less noticeable. This gives you better surface quality and haptics, reducing the need for any post-processing operations such as sanding.

Stiffness

3D-printed carbon fiber parts maintain their shape under high stress. In contrast with other materials that trade off strength and durability for stiffness, the rigidity possible with carbon fiber ensures structural integrity.

Requirements to Work with Carbon Fiber Filaments

Carbon fiber filament is more abrasive than many other materials and has specific heat requirements. As is typically the case with engineering-grade materials, they cannot simply be swapped out for standard 3D printer filament and be expected to print with the same settings.

3D printer bed with build plate and 3D printing of a carbon fiber reinforced part

Heated Print Bed

Hand-in-hand with an enclosed 3D printing environment is a heated print bed, which is crucial to ensure that the first print layer adheres to the print bed. Without this strong foundation, the success of the remaining print layers may be compromised.

Hardened Nozzle

Over time — which can vary from one to a few print jobs — carbon fiber filament will wear down a standard 3D printing nozzle due to its abrasiveness. A brass nozzle, for example, will wear out when extruding these materials and will ultimately be rendered functionally useless. Hardened steel is a requirement for a 3D printer to handle CF filament.

Of course, designers, engineers, and operators working with any CF-inclusive project must all be well-trained in the requirements for working with carbon fiber filaments. Training and upskilling must be considered when considering bringing CF filaments into operations.

3D printer creating car interior parts in a manufacturing facility

Print Orientation

The addition of CF increases tensile strength but when managed incorrectly it can lead to a reduction in layer adhesion. To compensate for the material's low ductility, orient the part in the direction of the stress or the load. This can be adjusted during the orientation of the part in a slicing software such as BLADE.

Composite Mould 3D Printed with Carbon Fiber Filament

Where are CF Filaments used?

Carbon Fiber 3D printing is best put to use in manufacturing environments thanks to its high strength-to-weight ratio and overall stiffness. Among the primary uses for these materials are the creation of molds, jigs and fixtures, and tooling.

Composite Molds & Thermoforming Molds

3D printed molds are one of the most cohesive ways advanced and traditional manufacturing technologies work together in an industrial environment. 3D printed molds offer the complexities and speed of production of 3D printing to the mass production capabilities of mold-based manufacturing. When it comes to composite molds and thermoforming molds, the performance properties of CF materials are a natural fit.

Composite molds are one of the most common manufacturing methods to cost-effectively produce large batches of identical parts. As their name implies, composite molds are made using composite materials, which can be made in complex shapes and stand up to repeated use — all at a significantly lower cost than aluminum or steel molds.

Thermoforming molds use heat and pressure to shape a flat thermoplastic sheet into a form using conduction, convection, or radiant heating to warm the sheet before conforming it to the mold’s surface. Thermoforming molds must stand up to repeated high-heat usage, requiring specific performance capabilities that can be well delivered via CF materials.

Jigs & Fixtures, Tooling

Often viewed as supplemental to manufacturing processes — but vital in their own right — are jigs, fixtures, and tooling, using in milling, drilling, and other subtractive operations. Jigs and fixtures are used to hold specific parts in place throughout different stages of their manufacturing, and tooling is used throughout.

These all-important tools often perform best when customized to the application at hand and may be worn out through highly repetitive use. For these reasons, jigs, fixtures, and tooling are increasingly 3D printed on-site. They can be custom-fit to their specific need and reproduced on demand without outsourcing or waiting to be restocked.

When made of reinforced materials like CF filaments, 3D printed jigs and fixtures and tooling last longer and perform better — especially in terms of long-lasting durability. You can learn more about replacing high-cost CNC milling with agile, cost-saving solutions for low-volume production here.

Automotive and Aerospace Industries

The design freedom of carbon fiber allows you to realize complex geometries that are not cost-effective with traditional methods. This design freedom enables you to rapidly iterate and then, due to its increased stiffness and temperature stability, create more functional prototypes. The enhanced aesthetics of the object, including complex curvature achieved with 3D printing and better surface quality with CF filaments, can open up innovation in automotive, aerospace, and other related industries.

Comparison of high temperature material vs PA12CF composite filament

BigRep PA12 CF and HI-TEMP CF

BigRep offers two carbon-filled filaments: PA12 CF, a nylon carbon fiber, and HI-TEMP CF, a bio-based, carbon fiber-filled polymer. The critical difference between these two carbon-filled filaments is that HI-TEMP CF has less demanding hardware requirements. HI-TEMP CF is applicable across multiple printers, including the ONE, the STUDIO, and the PRO, while PA12 CF is suited to industrial applications on the PRO.

If you want the best performance, then it's better to use a PA12 CF filament. PA12 CF possesses increased tensile strength, impact toughness, and heat deflection temperature, making it well suited to applications requiring superior durability and operational lifespan in challenging industrial environments.

The trade-off for HI-TEMP CF's higher stiffness, flexural strength, and less demanding printing requirements - compared to PA12 CF - is a slight reduction of impact toughness and heat deflection temperature. This makes it better suited to applications not exposed to impact but which maintain the need for dimensional stability under loading. This increased stiffness and flexural strength is provided by HI-TEMP CF.

No matter which filament you pick, taking advantage of the many benefits of carbon fiber-filled materials empowers you to increase the performance of your applications. Although specifically made for large-format printing on BigRep machines, these materials are compatible with most 2.85mm open printers with a hardened nozzle.

HI-TEMP CF

High Temperature Carbon Fiber Filament

Learn More

PA12 CF

Stiff and Strong Carbon Fiber

Learn More

Conclusion

When you decide to take on carbon fiber 3D printing, you’re committing to an endeavor that requires significant attention to parameters and specialized equipment and requirements. When those conditions are fulfilled, you can produce best-in-class lightweight, durable, functional parts that can stand up to a variety of industrial uses with all the complexity in design that 3D printing has to offer. Get in touch with a BigRep expert today to learn how CF filaments can help to improve your production capabilities.

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What is carbon fiber-reinforced material?
What are the best applications for carbon fiber?
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What Are the Benefits of Autocalibration?

January 20, 2023

To achieve the best possible results, 3D printers must be calibrated before printing. That includes the correct positioning of the print bed and the extruder(s) to eliminate dimensional deviations of the 3D print as much as possible. At the same time, correctly adjusting the distance between the nozzle and the print bed ensures good adhesion resulting in better overall quality, less warpage, and fewer failed prints.

The complexity of calibration depends on the type of printer, machine equipment, and application used. It requires knowledge and experience with the machine and is time-consuming and costly. Calibration can also become a significant time factor in the case of frequent material changes or a switch between an operation with and without dual extrusion. To address this, the new BigRep PRO offers autocalibration, taking this task off your hands and saving you time and money.

Autocalibration on the PRO - How Does It Work?

The first step to ensure a properly calibrated BigRep PRO is bed leveling. This can be done by running the 'bed level' function, which initiates the ball sensor to scan a number of points on the print bed. The PRO's user interface will report which areas are not level within an acceptable tolerance and then you simply adjust the bed screws. Bed leveling does not need to be done frequently, but only after initial installation or semi-annual check ups.

The BigRep PRO performs several calibration tasks before each print. The first is bed mapping, which is also used during the bed leveling process. In this case, a sensor ensures that the distance between the print nozzle(s) and the bed is the same over the entire surface of the print bed.

If inconsistencies are measured, the PRO can automatically adjust the thickness of the print layers to compensate for differences. This is particularly crucial for the first print layer, which is essential for successful adhesion between an object and the print bed. This can save you a lot of time on the BigRep PRO. Without precise calibration, the first layer is typically over-extruded to ensure that the print sticks on the printer bed, but this results in sub-optimal quality, as seen in the image below.

The print on the left is over-extruded. The print on the right has appropriate extrusion, a result of printer autocalibration.

Secondly, the PRO calibrates the distance between the two extruders. This alignment is paramount when bringing out the full benefit of dual extrusion. Only when the control software knows the exact distance between extruders can perfectly aligned structures be printed. Doing this step manually can take a lot more time. Automatic calibration also enables a superior level of precision to manual calibration.

How Does Bed Mapping Work?

The flatness of a print bed, which usually consists of a solid aluminum plate, is an approximation as the surface may slightly deform when heated. This is the case with everything on the FFF printer. However, the larger the print bed, the greater the deviation from the ideal flat surface. Since 3D printers from BigRep - such as the BigRep PRO - are among the largest machines available on the market, a perfect calibration is crucial.

With the aid of the sensor, a network of measuring points is recorded over the entire surface of the print bed. The relative height of each measuring point above an ideal theoretical surface is automatically stored in the software. This enables the printer to adjust the size of the print head—the result is a perfect first layer with a constant material thickness and ideal material adhesion.

The principle used for distance measurement has a direct influence on calibration precision. BigRep decided to use mechanical-inductive surface scanning for the BigRep PRO. Compared to purely inductive or optical methods, it is independent of surface conditions or appearance and allows the detection of printed structures.

A sensor scans the print bed to measure any minor inconsistencies, which are instantly analyzed to adjust the print layers to compensate for bed irregularities.

How Does Extruder Calibration Work?

There are some scenarios when dual extrusion is beneficial - or even necessary.

When printing several identical parts at the same time. Both extruders move in parallel, cutting production time per part in half and increasing productivity.
When printing a part using a support material. Since different extruders process both primary and support materials, they can use other materials. For example, they can combine a stable primary material with a water-soluble support material.
When printing two different primary materials in the same component. This procedure allows chemically identical materials to be combined with other colors to achieve visually desirable effects. Alternatively, materials having different mechanical properties can be combined.

In the first case, the exact alignment of the extruders to each other still plays a minor role, as it only influences the position of two parallel created objects on the print bed. These are usually made with sufficient spacing, while exact compliance does not affect print quality.

In cases 2 and 3, extruder calibration is very important. Since printing occurs in the same component, any offset of the extruders is immediately visible and noticeable on the print surface. Support material misalignment results in inadequate support functioning, causing unclean overhangs and concave horizontal surfaces. If different materials are used to print a single part, incorrect extruder calibration can lead to poor material bonding. There are also adverse effects on appearance and dimensional accuracy. The larger the print, the bigger the deviations, resulting in more sunk costs.

A sensor measures the printed structures to calibrate the dual extruders before printing.

At the push of a button, the BigRep PRO measures printed test lines and uses them to calculate the relative positions of the extruders. In this way, measurement errors are avoided.

Extruders 1 and 2 create two patterns that are offset from each other. The sensor scans the printed structures and determines their distance. These values are now stored in the machine control system and are used to achieve maximum accuracy during dual extrusion. Once the calibration is complete, your BigRep PRO is ready for precise printing.

Get in touch with us to learn more!

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COMPLEX PARTS IN LARGE SCALE.

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About the author:

Michael Eggerdinger

Business Manager Materials

Michael is a toolmaker, a mechanical engineer, and a patent engineer. His years of working in manufacturing and as a project manager in various industries provide him with a profound knowledge of the main challenges in modern production processes. In 2017, he bought his first 3D printer to be used at home, and he has been hooked ever since!

3D Printing Saves Time and Money as Airbus Innovates R&D Processes

April 29, 2024January 10, 2023

Even though airplanes are flying machines packed with technology, passengers typically perceive them as cramped yet passably comfortable traveling environments. Covers and panels hide all the actuators, cables, and electrical and mechanical devices in the plane walls. They also safely shield functional components from passengers while also contributing to the look and feel of the interior cabin space. These panels are commonly made from fiberglass composite materials due to the combination of low weights with high stiffness and load-bearing capabilities.

Large Parts Traditionally Require Expensive Manufacturing Techniques

Each version of a cover or panel commonly requires mold manufacturing. Glass fiber mats soaked with resin are placed, thus shaping the final panel after curing the resin. This process is time-consuming. It easily takes six to eight weeks to make one larger panel. Additionally, the high amount of manual labor involved causes substantial costs.

Engineers quickly realized that the BigRep ONE could be used in many other areas of research and development.

Product development requires evaluating and improving each design iteration until the best solution is reached. In some cases, designs can be checked through software evaluation. However, many situations require the creation of a physical prototype to properly evaluate its scale, fit, performance, aesthetics, and more. Having a physical object available also facilitates testing of mounting and assembly procedures.

Traditionally, aircraft interior panel prototypes would require CNC machining a mold before hand-laying the fiberglass and finishing the surface. Airbus would typically outsource the CNC machining, which meant they would wait weeks before starting the fiberglass process. Since each new iteration requires a new mold, the process is highly time-consuming and expensive. In many cases, prototypes would not be produced, denying the engineers the chance to improve designs before the final product was produced.

Airbus 3D Printing Airplane Cabin Panels

3D Printing Saves Time and Money During the Development Phases

Highly functional parts like aircraft doors require sophisticated panels, combining technical capabilities with an aesthetic appearance. The hinges, for example, need covers that match the cabin's interior design while also meeting performance and safety benchmarks. Since traditional fiberglass construction for airplane interiors is slow and costly, this restricts the manufacturer's ability to iterate and improve their designs.

Airbus would typically outsource the CNC machining, which meant they would wait weeks before starting the fiberglass process.

Airbus found a solution to this problem in the BigRep ONE 3D printer, which they had originally purchased to support helicopter development. Engineers quickly realized that the BigRep ONE could be used in many other areas of research and development. They began to print prototypes for aircraft interior components. While the Airbus engineers had experience with additive manufacturing on a smaller scale with desktop printers, they realized the enormous advantages of the BigRep ONE's one cubic meter build volume, which allowed them to 3D print prototypes of panels, linings, and covers in full scale, true to size.

How Does Airbus Benefit From BigRep Large Format 3D Printing?

With their BigRep ONE, Airbus engineers can 3D print the part, evaluate it, redesign it, and repeat it as needed until the design is finalized. An added advantage of their in-house BigRep 3D printer is eliminating the long lead times and additional logistics for outsourcing mold production. Relying on full-scale 3D prints for the cycles of design iteration makes this process much more straightforward while saving time and money.

For large parts accurate enough for implementation into aircraft interiors, Airbus engineers relied on BASF's Ultrafuse PRO1 filament to 3D print their prototypes. PRO1 is easy to print and results in a beautiful surface finish without any warping. Airbus engineers noted that the precision of 3D printed prototypes are sufficient for their defined tolerances - particularly for large parts - so they can reliably create and test designs that are very close to the finished product.

While Airbus is constantly 3D printing prototypes with their BigRep ONE, they expect to use it in other areas. Having already learned that they can save a lot of money with 3D printed solutions, the Airbus engineers currently use desktop 3D printers to create some tooling. Their future plans will make use of the one cubic meter build volume of their BigRep 3D printer to produce large scale factory tooling. Learn more about the BigRep ONE here.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

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LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

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About the author:

Michael Eggerdinger

Business Manager Materials

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3D Printed Weirs for Hydraulics Research

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Large Format 3D Printing in Research Institutes

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Lindsay Lawson

What is a Gyroid?

Understanding Gyroid Infill:

Advantages of Gyroid Infill in 3D Printing:

Low warping:

Enhanced Strength and Structural Integrity:

Significant Weight Reduction:

Material Efficiency and Cost Savings:

Improved Heat Dissipation:

Enhanced Flexibility and Impact Resistance:

Excellent Filament Flow:

Disadvantages of Gyroid Infill in 3D Printing:

Longer Slicing Times

Limited Control Over Internal Geometry:

Reduced Transparency and Visual Clarity:

Applications and Use Cases:

Functional Prototypes:

Mechanical Components:

Lightweight Structures:

Artistic and Decorative Prints:

Implementation and Tips for Using Gyroid Infill:

Conclusion:

Want to Learn More About Gyroid Infill?

About the author:

Dominik Stürzer

Responsive car seat enabled by large-format 3D printing showcases innovation potential for additive manufacturing in the automotive space.

A Multi-Partner Effort

“What if the seat were to become a partner that reacts and responds to our actions, an organism, a friend, that lives and breathes?”

Conceiving of ‘Concept Breathe’

Paving the Way for Innovation

3D Printing is the Future of Automotive

How to Choose Which Features You Need on a Modular BigRep ONE

Which Features Does the BigRep ONE.4 Already Have?

Massive Print Volume

Enclosed Safe Frame

PEX Fiber-Ready Extruder

Semi-Automated Print Bed

Out-of-Filament Sensor

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SINGLE MODE

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Which Additional Add-Ons Are Available?

Keep-Dry Add-On

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

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

Design for Additive Manufacturing:
Best Practices for Superior 3D Prints