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BANYAN Eco Wall – The World’s First Fully 3D Printed, Irrigated Green Wall

BigRep is proud to present the BANYAN Eco Wall, the world’s first fully additively manufactured (AM) green wall with naturally integrated drainage and irrigation systems. The prototype features unprecedented innovations in design, functionality, technology and size, made possible with the BigRep ONE’s large-format additive printing process.

Designed at NOWLAB, BigRep’s innovation consultancy, by Mirek Claßen, Tobias Storz and Lindsay Lawson, the project features liquid channels that have been integrated into the manufacturing process. Similar vertical-farm structures have required channels to be manually embedded into the design in a complicated process after manufacturing with metal piping and a variety of other parts. The BANYAN, on the other hand, is 3D printed with internal channels included in the design. This allows for ultimate design freedom, as the eco wall’s structure doesn’t need to be planned around the available materials to create channels in post-production. These drainage systems are vital for the proper function of the integrated irrigation system, as excess water must be removed.

Irrigation systems, implemented to provide a controlled supply of water at requisite intervals, ensure the unique needs of plants and crops are met without the need for human intervention. Systems such as this inspire interior designers and architects developing a greener future – from home or workspace plant walls and green facades to vertical gardens and other forms of urban farming.

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Inspired by the multipurpose properties of plants’ root, steam and leave systems, the design of the BANYAN Eco Wall takes advantage of biomimicry design to create a structure that simultaneously functions as a support structure and water supply system. Its bionic design, measuring 2000 x 2000 x 600 mm, goes beyond aesthetics to be structurally optimized with plant carriers that easily and organically snap into place. The small internal channels are designed for optimal water flow and feature an integrated “micro shower” mechanism to irrigate plants precisely where needed.

“Our BANYAN Eco Wall is adopting nature’s principle with a complex, smart, and elegant design only achievable with AM. Traditional technologies such as milling or injection molding cannot deliver this level of complexity and dual functionality,” explains BigRep CEO Stephan Beyer, PhD. “For the first time, thanks to AM and advanced CAD software, it is now possible to create complex functional designs within a fully digitized process chain.”

BigRep CIO and NOWLAB Managing Director Daniel Büning adds, “Generative design software was crucial in the creation of the BANYAN Eco Wall to optimize the structure for printability and stability while allowing a rapid iterative design process. This prototype will push the boundaries of AM not only in irrigated plant systems, such as in vertical farming and green facades, but for any application requiring embedded functionalities.”


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The BANYAN ECO WALL at a glance:
Dimensions: 2000 x 2000 x 600 mm, made up of 4 segments
Materials: BigRep Berliner Weisse Pur PETG for overall structure; BigRep Black PRO HT for planters
Team: Daniel Büning, BigRep CIO and NOWLAB Co-Founder
Lead Designers – Mirek Claßen, Tobias Storz, Lindsay Lawson

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BigRep Wins Creative Use at the 3D Printing Industry Awards 2019

Last week, BigRep was proud to participate in the prestigious 3D Printing Industry Awards! We had the honor to be nominated in three categories and to receive the Creative Use of 3D Printing award for the NERA eBike – our fully 3D printed e-motorcycle.

BigRep was represented at the event by Mirek Claßen, NOWLAB Head of Innovation and Generative Design Applications, and Jan Hoffmann, Head of Software, who received the award on the company’s behalf.

“We are thrilled about the award for our prototype NERA, the world’s first fully 3D-printed, functional e-motorcycle,” said Daniel Büning, NOWLAB co-founder and Head of Innovation “With our creative use of 3D printing, we have demonstrated the unprecedented capacity of FFF large-scale 3D printing technology in AM.”

The NERA development was led by Marco Mattia Cristofori at BigRep’s internal innovation consultancy, NOWLAB, to demonstrate the incredible developments that can be accomplished with today’s accessible additive manufacturing technology, like BigRep’s large-format 3D printers. The NERA dispels many of the assumed limitations of additive technology, such as its applicability for end-use parts.

“To us, the award also confirms BigRep’s ability as an innovation leader bringing new technologies from design to reality – in this case in only 12 weeks – providing an added-value market lead for industrial customers.”

The award-winning e-motorcycle was printed with a combination of consumer-friendly industrial filaments including BigRep Pro Flex, BigRep Pro HT, BigRep PLA, and BigRep PETG materials. Pro HT was used for rigid parts, PLA for color details and PETG for the light reflectors. Pro Flex allowed for embedded functionalities in a unique way; tires, bumper, seat and handles were printed with the flexible material to effectively fulfill functions that usually require complex mechanical constructions like hydraulic, shock absorbing suspension systems.

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The monumental success of the NERA, its development and execution with additive technology, shows how processes are ripe for re-thinking with a totally new, future-forward additive perspective to change the way designers envision products.

The NERA eBike and other challenging projects like it are taken on by BigRep’s innovation and consultancy department, NOWLAB, with clients working on similarly incredible projects that push 3D printing to its limits and uncover the technology’s true capabilities. The NERA is just one example of revolutionary applications that companies at the forefront of their industries are capable of with large-format additive manufacturing at their disposal.

Want to stay up to date on the latest BigRep news? Subscribe to our newsletter and be the first to know or request a demo.

About BigRep:

BigRep develops the world’s largest serial production 3D printers, creating the industry benchmark for large-scale printing with the aim to reshape manufacturing. Its award-winning, German-engineered machines are establishing new standards in speed, reliability and efficiency. BigRep’s printers are the preferred choice of engineers, designers and manufacturers at leading companies in the industrial, automotive and aerospace sectors. Through collaborations with its strategic partners – including Bosch Rexroth, Etihad Airways and Deutsche Bahn – and key investors – including BASF, Koehler, Klöckner and Körber – BigRep continues to develop complete solutions for integrated additive manufacturing systems, as well as a wide range of printing materials on an open-choice source. Founded in 2014, BigRep is headquartered in Berlin with offices in Boston and Singapore. Leading the way in one of the world’s key technologies, our multinational engineering teams are highly trained, interdisciplinary and customer-focused.

For more information on BigRep and its solutions and to arrange an interview with BigRep CEO, Stephan Beyer, PhD, or BigRep CBO, Frank Marangell, and, please contact:

Juergen Scheunemann
PR & Communication
PR & Communications BigRep GmbH
T +49 30 9487 1430
E [email protected]
Abbey Delaney
North American Marketing Manager BigRep
M (989) 860 – 8210
E [email protected]

First BigRep PRO installed at Boyce Technologies, Inc.

The highly anticipated innovative BigRep PRO has landed in New York at Boyce Technologies, Inc. This marks the first official installation of the PRO, powered by the new BigRep Metering Extruder Technology (MXT®) and state-of-the-art Bosch Rexroth CNC control system. Boyce Technologies is taking their additive process to the next level by adding the PRO to their already existing 3D printing workhorse, the BigRep STUDIO.

Boyce Technologies’ use of additive has grown rapidly from prototyping to printed molds for vacuum forming and manufacturing end-use parts additively. Presently, several end-use parts are produced with BigRep printers at Boyce Technologies for Verizon kiosks placed across New York City.

“With the PRO, we are now much more competitive because we’re able to produce large proofs of concepts faster than anyone else in the industry,” said Ajmal Aqtash, Director of Robotics at Boyce Technologies. “We’re a company known to move really fast. It’s our competitive advantage, and now with the PRO our additive capabilities have increased five times.”

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Boyce Technologies houses an ecosystem of industrial manufacturing tools that the PRO, their second BigRep printer, has joined. A unique solution, the PRO answers industry demands with a variety of powerful technologies working in tandem. BigRep’s powerful MXT technology is harnessed for fast, precise and astoundingly repeatable large-format prints. The Bosch Rexroth CNC control system facilitates 5G compatible data collection to monitor and optimize the BigRep PRO’s powerful additive manufacturing capabilities.

Want to learn more about Boyce Technologies’ additive activities? Watch our on-demand webinar with Ajmal Aqtash, Boyce Technologies Director of Robotics.

Daniel Büning Appointed Chief Innovation Officer of 3D Printing Manufacturer BigRep

3D design, technology and innovation expert Daniel Büning, co-founder of NOWLAB, named as new Chief Innovation Officer of BigRep GmbH / Appointment completes BigRep executive management team.

Berlin, 23 April 2019 - BigRep, the global leader in large-scale 3D printing and supplier of Additive Manufacturing (AM) solutions, has named Daniel Büning as its new Chief Innovation Officer.

In his new role, Daniel Büning (37) will focus on industry-driven applications by managing BigRep’s technological innovations, conceptualizing new visions, prototypes and future solutions for AM. The CIO will also oversee two key areas of expertise – the development of sustainability as well as the integration of digital technologies in 3D printing such as machine learning and AI.

Daniel Büning is no stranger to AM and BigRep. A pioneer in the field of large-format AM, in 2014, he was a co-founder of NOWLAB, which joined BigRep two years later. Leading NOWLAB, the digital technologies and innovation hub within BigRep, he and his team of engineers and designers have been the driving force behind the company’s groundbreaking prototypes. Many of these, including the NERA e-motorbike, the Adaptive Robotic Gripper and the AGV Next mobile industry platform, were industry-first developments, establishing BigRep as the thought leader in large-format 3D printing.

BigRep CEO Stephan Beyer, PhD, said: "BigRep is advancing toward digital production solutions delivering reliable technology for our customers. The focus of his responsibilities on applications, sustainability and digital technologies in 3D printing reflects our ambition to lead the way. This appointment shows our appreciation of Daniel’s proven track record and the performance of his whole team; his know-how and experience across different industries will be a great asset to BigRep. Being a trusted partner of our stakeholders as well as a highly respected team member, we welcome Daniel to the executive team and look forward to working with him.”

The German-born architect (Münster School of Architecture) has enjoyed an excellent academic career, including a Fulbright scholarship and studies at the renowned Pratt Institute in New York City, one of the leading art schools in the United States. Looking back on ten years in digital design, manufacturing, 3D printing and AM, he has also served as a guest lecturer at universities and institutions such as the AA London, The Royal Danish Academy of Fine Arts and the University of Arts Berlin. In addition, he has been selected as an expert for digitalization and Industry 4.0 issues in proceedings at the German federal parliament.

“I’m thrilled about my new responsibilities at BigRep”, said Daniel Büning. “This is a highly dynamic company, whose visions I am excited to support and develop ground-breaking innovations for our expanding global industrial customer base. BigRep is driven by a passion for technical transformation and service; a set of values I deeply share and to which I will contribute with my know-how and experience.”

About BigRep:

BigRep develops the world’s largest serial production 3D printers, creating the industry benchmark for large-scale printing with the aim to reshape manufacturing. Its award-winning, German-engineered machines are establishing new standards in speed, reliability and efficiency. BigRep’s printers are the preferred choice of engineers, designers and manufacturers at leading companies in the industrial, automotive and aerospace sectors. Through collaborations with its strategic partners – including Bosch Rexroth, Etihad Airways and Deutsche Bahn – and key investors – including BASF, Koehler, Klöckner and Körber – BigRep continues to develop complete solutions for integrated additive manufacturing systems, as well as a wide range of printing materials on an open-choice source. Founded in 2014, BigRep is headquartered in Berlin with offices in Boston and Singapore. Leading the way in one of the world’s key technologies, our multinational engineering teams are highly trained, interdisciplinary and customer-focused.

Contact:

Juergen Scheunemann
PR & Communication
PR & Communications BigRep GmbH
T +49 30 9487 1430
E [email protected]

Ready to Fly: The World’s First Fully 3D-Printed High-Tech Airline Seats to be Premiered by BigRep at Aircraft Interiors Expo in Hamburg

Two innovative aerospace seats envisioned with Dassault Systèmes’ 3DEXPERIENCE platform and the industry solution experience “Passenger Experience” / The Retro Seat saves 50 percent of original seat weight, while the cutting-edge bionic Aero Seat offers an all-new passenger experience.

Hamburg / Germany, April 1, 2019 - BigRep, the global leader in large-scale 3D printing (FFF segment) for industrial applications, will unveil the world’s two first fully 3D-printed aerospace seat systems with Dassault Systèmes at the Aircraft Interiors Expo in Hamburg (April 2-4, 2019). Both prototypes have the potential to re-define aircraft interiors’ design as well as the passenger experience in air travel.

Opening a new dimension for Additive Manufacturing (AM) in the aviation industry, the prototypes, designed by NOWLAB, the BigRep innovation consultancy department, and manufactured on BigRep’s large-scale 3D printers, include the Retro Seat, an original airline seat which has been refurbished by using AM, and the Aero Seat, a bionic passenger seat. Strikingly elegant, both seats present visionary design unprecedented in 21st century aircraft interior composition.

aix-blog-2

Both full-size seat systems were created using Dassault Systèmes’ 3DEXPERIENCE platform and the industry solution experience “Passenger Experience”. Engineers use 3D printers to produce optimized parts by leveraging the 3DEXPERIENCE platform to design and simulate highly optimized parts based on space allocation, loads, constraints, manufacturing processes, and multi material requirements.

“Our Retro Seat saves 50 percent of weight, creating huge benefits for sustainable aircraft engineering and operational costs. Our prototypes demonstrate the massive benefits of 3D printing for manufacturers and airlines,” said Daniel Büning, co-founder and Managing Director of NOWLAB at BigRep. “In addition, jigs, fixtures and other cabin interior parts can be printed on site and on demand. In cabin interior design, 3D printing will push the limits of engineering creativity. For designers, the 3DEXPERIENCE platform will be a key tool in this process.”

“3D printing is in the process of re-defining the aviation industry, and we’re ready to fly! Our new 3D printer PRO offers an unprecedented level of precision, quality and speed, enabling us to use the high-performance, innovative printing materials the aviation industry requires.” said BigRep CEO Stephan Beyer, PhD.

BigRep and Dassault Systèmes will show how AM can be applied to any part of the cabin – from seat to armrest to sidewall panel as well as how AM enables design of individual end-use parts starting from lot size one to small series production.


Find out how industry leaders are using BigRep 3D printers to create affordable and secure investment shipping containers on demand for sensitive aerospace equipment in our case study with Airbus:
Read Now

Making full use of the unique technical possibilities of 3D-printing, the Retro Seat offers groundbreaking high-tech features such as inductive charging that permits wireless charging of smartphones. The back of the headrest is equipped with “Bring your own device” outlets to connect to tablets or other devices as well as multiple USB ports. The seat is also embedded with blue LED light panels, creating ambiance during night flights, while the arm rest is equipped with a smart cabinet solution to safely store laptops during takeoff and landing.

The Aero Seat presents a game-changing passenger seat for autonomous driving technology. This exciting seat shell design has an almost bionic touch, look and feel as the seat will adapt to the driver’s or passenger’s individual body shape: Using a 3D body scan prior to the seat production, the shell will provide its users with an unprecedented level of comfort to reduce stress and physical discomfort during long trips. Last but not least, flexible materials are being used for printing seat cushions (incl. softness factor).

Both designs are not a simple adaptation of existing, convectional airline seat frameworks, but were specifically envisioned for large-format FFF technology, setting a benchmark example for truly creative design by breaking the limits of traditional engineering. For example, both seats have a fully integrated design, i.e. any bearings or electronics can be integrated during the printing process.

BigRep will be present at this year’s Aircraft Interiors Expo at Dassault Systèmes’ booth 6C90E in the Hanse Pavilion.

aix-blog-3

About BigRep:

BigRep develops the world’s largest serial production 3D printers, creating the industry benchmark for large-scale printing with the aim to reshape manufacturing. Its award-winning, German-engineered machines are establishing new standards in speed, reliability and efficiency. BigRep’s printers are the preferred choice of engineers, designers and manufacturers at leading companies in the industrial, automotive and aerospace sectors. Through collaborations with its strategic partners – including Bosch Rexroth, Etihad Airways and Deutsche Bahn – and key investors – including BASF, Koehler, Klöckner and Körber – BigRep continues to develop complete solutions for integrated additive manufacturing systems, as well as a wide range of printing materials on an open-choice source. Founded in 2014, BigRep is headquartered in Berlin with offices in Boston and Singapore. Leading the way in one of the world’s key technologies, our multinational engineering teams are highly trained, interdisciplinary and customer-focused.

For more information on BigRep and its solutions and to arrange an interview with BigRep CEO, Stephan Beyer, PhD, or BigRep CBO, Frank Marangell, and, please contact:

Juergen Scheunemann
PR & Communication
PR & Communications BigRep GmbH
T +49 30 9487 1430
E [email protected]

Omni Platform by NOWLAB

NOWLAB, the Innovation Consultancy at BigRep, developed the innovative Omni Platform as a 360° mobile industry platform for highly flexible applications in automated manufacturing environments and smart factories.

The Omni Platform gets its name due to its mecanum wheels, which are omni-directional wheels, meaning they can move the platform in any direction without turning. The mecanum wheels are wheel hubs fitted with integrated rollers that move passively and independently. Depending on which wheels rotate in which direction, the platform will move forward, backward, sideways, diagonally, or spin in place. This range of maneuverability enables the Omni Platform to efficiently navigate any space, particularly around tight corners, narrow lanes, and complex pathways.

The benefit of 3D printing, including this case of the Omni Platform, is that it is 100% customizable to your specific needs. The body of the Omni Platform features a bionic design, intelligently modeled for strength and durability. It has an impressive load capacity of up to 200 kg and a load area of 100 by 80 cm. While this Omni Platform is an automated logistics carrier fitted with an acrylic top plate so that it can carry any number of objects, it can also serve as a platform for additional devices such as robots, for example, to be mounted.

wheel-web

The 3D-printed platform has a fully integrated design, i.e. any bearings or electronics can be integrated during the printing process. The Omni Platform has a controller and battery housed in a customized 3D printed “heart” as well as integrated motors, transition belts, gears, and programmable LEDs.

The Omni Platform was printed on a BigRep ONE with an impressive build volume of one cubic meter. Therefore, the platform body could be printed as a single part. For this, BigRep’s Pro HT material was used because it is durable, reliable, and produces beautiful quality prints. The mecanum wheel rollers were printed with BigRep’s Pro Flex, a flexible and robust TPU material that ensures better grip and smoother rolling.


Find out how industry leaders are using BigRep 3D printers to create affordable and secure investment shipping containers on demand for sensitive aerospace equipment in our case study with Airbus:
Read Now

Omni-Platform-Diagram-web

NOWLAB works to make the most advanced, innovative, and yet unseen applications and technological solutions in the additive manufacturing domain. The Omni Platform is designed to seamlessly integrate into in the factory of the future, helping to automate and accelerate production in Industry 4.0.

Contact NOWLAB

About BigRep
BigRep develops the world’s largest serial production 3D printers, creating the industry benchmark for large-scale printing with the aim to reshape manufacturing. Its award-winning, German-engineered machines are establishing new standards in speed, reliability and efficiency. BigRep’s printers are the preferred choice of engineers, designers and manufacturers at leading companies in the industrial, automotive and aerospace sectors. Through collaborations with its strategic partners – including Bosch Rexroth, Etihad Airways and Deutsche Bahn – and key investors – including BASF, Koehler, Klöckner and Körber – BigRep continues to develop complete solutions for integrated additive manufacturing systems, as well as a wide range of printing materials on an open-choice source. Founded in 2014, BigRep is headquartered in Berlin with offices in Boston and Singapore. Leading the way in one of the world’s key technologies, our multinational engineering teams are highly trained, interdisciplinary and customer-focused.

For additional information, please contact:
To arrange an interview with BigRep’s executive management or NOWLAB team, and for more information on BigRep and its solutions, please contact:
Jürgen Scheunemann
PR & Communications BigRep GmbH
T: +49 30 9487 1430
E: [email protected]

NEXT GENERATION LARGE-SCALE 3D PRINTING – Webinar Q&A

Our next generation webinar was a great success with guests joining from all over the world to listen to Frank Marangell, President of BigRep America Inc, and Abbey Delaney, Marketing Manager, discuss the limitations of old FFF technology, why the additive manufacturing market needed a solution, and what BigRep’s new MXT technology®, which powers our latest industrial printers—the PRO and the EDGE—will do for large-scale, industrial 3D printing.

The webinar closed with a dynamic Q & A session, but unfortunately, we didn’t have time to answer all of your questions, so in this article we will dive deeper into what listeners really wanted to know about BigRep’s next generation 3D printers.

What is the layer thickness options and Z build rate at layer height 1,2,3 etc?

The MXT has all the flexibilities in layer heights of a traditional extruder. Specifically, since the extrusion is very fast, the first release is using a 0.6 mm nozzle, for which we recommend a 0.4 mm layer height—a finer resolution is also possible.

Could you specify the max working extruder temperature for the PRO?

The max extruder temperature is 300C as the extruder is designed for a wide range of materials.

Is the max throughput of 1,000 mm/s reliable for long prints?
Certainly. Both the BigRep PRO and the EDGE were built to print large parts and to run in industrial environments—around the clock. The maximum speed at which the X-Y gantry can move is 1,000 mm/s on the EDGE. The PRO has printing speeds of up to 600 mm/s, with throughput of around 400 cm³/ hour.

What speed and acceleration should xy motors move in order to keep up with these extrusion rates?
The speed and acceleration are dynamically set by the Bosch CNC control system to allow for an optimal printing experience and material performance.

What is the accuracy of the PRO and the EDGE?
The accuracy of the printers is considerably better than their predecessors the ONE and the STUDIO, but the important factor is repeatability: the repeatability is much higher than any other extrusion printer on the market, awakening the potential of large-scale industrial 3D printing.

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Could you share more details about the new toolpath generation? What makes it so innovative?
The new toolpath is optimized for high-speed and stability and is currently still in development. Stay tuned to our blog for more details as they emerge.

How much do the printers cost?
If you are interested in receiving additional pricing information, please submit a request here.

How does the internal structure of printed parts appear on the EDGE, as compared to the ONE, in reference to the slide titled ‘how it really looks’?
As the EDGE is pre-beta, we have yet to formally compare the internal structure, but we will publish results in 2019. A study of the PRO will be published early in 2019.

According to the material compatibility table, neither the PRO or the EDGE can use PLA. Can you confirm?
The PRO and the EDGE are industrial materials printers; nevertheless, the target applications for the PRO and the EDGE are in the area of industrial/technical plastics—not PLA. However, the BigRep ONE and STUDIO are PLA compatible.

Is it possible to use two spools of two different types of filaments, using the same fusion temperature?
Although the same melting temperature does not mean the same extrusion characteristics, in general, the use of two different types of filament is achievable, but this needs to be tested and validated, prior to its release.

Regarding materials, are you looking into developing polymers with low CTE, as this will expand the use of AM for aerospace composite cure tooling?
The materials we develop and release in 2019 will unlock new applications for forms and molds—including aerospace applications. With reference to technology and the temperature of the various systems, it all depends on the resin systems used for its components. The curing of parts after production is also possible at 60°C. BigRep is currently speaking with prospective clients to gain insight into their requirements. Knowledge sharing is essential to help advance the additive manufacturing industry.

What printer will PEEK material be available on?
The EDGE—the industry leader for high-end thermoplastic materials.

How do support materials work on BigRep machines?
This is where the second extruder comes in to play: this enables the support material to work. BigRep will introduce special support materials for high-end/high-temp build materials.

Are there any food safe plastic filaments offered by BigRep?
PETG is already available and it is FDA approved (https://bigrep.com/wp-content/uploads/2018/08/BigRep-Technical_Specification-PETG.pdf) Furthermore, PP is on the materials roadmap and PC also. FDA compliant BigRep materials: PLA, PVA, ProHT, ProHS, and PETG.
With respect to food safety, the material used is one thing, the complete process of producing food products for consumption is a whole other thing.

What is the max temperature capability of your materials from an end use application perspective?
The max extruder temperature is 450° C or 842° F.

Are the materials listed for the PRO and the EDGE all plastic based or can these be printed with metal?
We are an industrial 3D printing company, specifically a thermoset plastics company. There is no plan to print with metal in the future.

Can this new system work with a carbon filled polymer like Nylon?
We are in the development/testing phase with fiber filled plastics. Watch this space!

Frank-Marangell-bigrep

Frank Marangell is President of BigRep America Inc. and Executive VP of Global Sales at BigRep. He has been operating at the top level of the additive manufacturing industry for over a decade.

Connect with Frank on Linkedin HERE.

Next Generation Large-Scale 3D Printing Webinar

Large-scale 3D printing is on the brink of transforming additive manufacturing (AM) and BigRep’s next generation of engineering-grade printers—discussed in detail during the webinar—set a new standard for the industry. If you joined us for the live webinar, we hope that you enjoyed it, however, if you missed it, you can still watch a recording of the full webinar here or read on for a summary.

Frank Marangell, President of BigRep America hosted the webinar with the help of Abbey Delaney—Marketing Manager.The webinar took guests on a journey from traditional FFF technology and its limitations to BigRep’s next generation of industrial 3D printers: the BigRep PRO and the BigRep EDGE, both equipped with new MXT®—Metering Extruder Technology, which solves two of the fundamental limitations of FFF technology: low throughput and low repeatability.

The BigRep Strategy

The question was posed: what makes BigRep different from other AM manufacturers? First, BigRep is application led and customer-centric. That means that value-added, and innovative parts are identified, designed and built before materials and systems are put in place. Presently, new applications are coming on the market from functional prototyping, jigs and fixtures, to end-use parts. The evolution of AM from experimental prototyping to industrial end-use parts happened at lightning speed—and Fortune 500 companies now see the commercial benefits. As companies like Ford, Daimler, Etihad, Toyota and Boyce Technologies—customers of BigRep—turn to AM for faster product development, on-demand spare parts, and futuristic applications; it’s clear that AM has shifted in its utility for the manufacturing sector.

Traditional FFF Technology

“If it melts, we can print it,” said Moshe Aknin, Chief Technology Officer, referring to standard FFF/thermoplastic extrusion print technology. Indeed, FFF can produce very good dimensional repeatability with good dimensional stability. It’s on these pillars that additive manufacturing progressed from small, basic printed models to the latest revolution—large-scale industrial AM.

However, with disappointing throughput, and low repeatability, FFF’s functionality beyond experimental design, has until now, disappointed engineers. Moreover, with the relatively low surface quality of printed parts, the industry plateaued—since the commercialization of FFF in the early ‘90s.

Metering Extrusion Technology

Why the Low Throughput?

In order to understand why throughput was previously low, you need to look at the basic concept of FFF: either a gear/wheel mechanism pushes a filament into a hot nozzle, or a screw mechanism pushes polymer pellets into a hot nozzle.

So, you have a very fast reaction process—the movement—and a very slow process—the melting. They need to be synchronized to have a precise deposition of the material. Thus, the previous solution was to slow everything down—to a speed that the thermal melting process allowed. Thus low repeatability is a consequence of producing a 3D object without controlling the flow of the material. With many industrial 3D printers, the volume of material extruded is unknown.

New Frontier in Additive Manufacturing

Evidently, the market demanded a solution, so BigRep pioneered the MXT® (Metering Extruder Technology.) The result: transformative throughput and high repeatability; two unique selling points of BigRep’s next generation of large-scale 3D printers—the BigRep PRO and the BigRep EDGE.

BigRep’s MXT® (Metering Extruder Technology) is set to redefine additive manufacturing. When compared to traditional FFF technology, the new innovation by BigRep, is capable of printing speeds of 1,000 mm /s—on the BigRep EDGE and exceeding 600 mm /s on the PRO. Importantly, these print speeds are achievable without diminishing the accuracy of the print. Marangell, who has decades of experience in additive manufacturing, explained in detail how MXT® works and why, with controlled extrusion and a Bosch Rexroth CNC system—a new level of throughput is possible.

Furthermore, BigRep’s materials are developed in partnership with BASF—the largest chemical producer in the world. Engineering-grade materials, now possible on the BigRep PRO extend the possible applications for large-scale 3D printing—once a major barrier in industrial AM. Thermoplastic materials can now be used in both new printers, but the BigRep EDGE, due to be released in Q2 2019 has an even wider range of high-performance materials such as ABS/ASA, PC, PP, and PEI (Ultem.)

New Printers: The PRO and the EDGE

BigRep has set a new standard for the industry, with the release of the PRO and the EDGE, our next generation printers—that respond to industrial demands. Now built with a state-of-the-art Bosch CNC system, enclosed build chambers, and MXT® technology.

The EDGE, which is due to be released in Q2 2019, promises to reshape AM as we know it—with high-performance materials, speed, and precision extrusion. The webinar drew to a close with a ten-minute questions and answers session, with questions rolling in from industry enthusiasts, across the globe.

Watch the full webinar here.

Frank-Marangell-bigrep

Frank Marangell is President of BigRep America Inc. and Executive VP of Global Sales at BigRep. He has been operating at the top level of the additive manufacturing industry for over a decade.

Connect with Frank on Linkedin HERE.

Etihad Airways Engineering to use BigRep 3D Printers in their Maintenance, Overhaul and Repair facility

3D Printed parts on site and on demand: Etihad Airways Engineering to use Bigrep 3D printers in their Maintenance, Overhaul and Repair facility.

Etihad Airways Engineering to install large-scale 3D printer BigRep ONE to print parts and tooling, followed by a next generation BigRep EDGE industrial 3D printer to develop, test and certify material for aircraft parts.

BigRep, the global leader in large-scale 3D printing, and Etihad Airways Engineering have announced today that the airline MRO will deploy a BigRep ONE 3D printer in its Maintenance, Operations and Repair facility at the Etihad home base in Abu Dhabi. The printer will be used in daily operations to print jigs, fixtures and (non-flying) parts on site and on demand.

Its arrival highlights the first phase in a partnership between BigRep and Etihad Engineering established earlier this year, with the aim to jointly develop, test and certify new materials for 3D-printed aircraft cabin parts. With the introduction of the new industrial 3D printer PRO, BigRep is moving forward to the production of end-use parts for the aerospace industry.

Find out how automotive industry leaders have upscaled
their in-house tooling using BigRep 3D printers in our
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Bernhard Randerath, Vice President Design, Engineering & Innovation of Etihad Airways Engineering says: “We are at the forefront of bringing this exciting technology into aviation and will work with our partners to ensure a successful certification of 3D printing technology, and with it towards the vision of a 3D-printed cabin.”

Stephan Beyer, CEO of BigRep GmbH, says: “Thanks to our 3D printers, we will accelerate the use of Additive Manufacturing in the aviation industry. With the BigRep PRO and EDGE, we will be able to unfold the full potential of our technology, together with Etihad Airways Engineering. These machines offer an unprecedented level of precision, quality and speed, and enable us to use the high-performance, innovative printing materials the aviation industry requires.”

As an innovation leader, Etihad Airways Engineering will leverage its experience around the aircraft cabin and will provide its design organisation approvals, as well as production organisation approvals and in-house flammability lab to test the 3D printed parts. In particular, BigRep’s large-scale 3D printers are suited to printing large cabin parts with the possibility of a high level of customisation – one of the most challenging requirements in the airline industry.

In addition, the aim is to jointly develop and test new material grades in accordance with EASA and FAA criteria, as there is a need for a wider spectrum of AM-suitable polymer materials that can pass the aerospace certification process.

About Etihad Airways Engineering

Etihad Airways Engineering is the largest commercial aircraft maintenance, repair and overhaul (MRO) services provider in the Middle East. As a subsidiary of the Etihad Aviation Group, the company offers maintenance services around the clock, including design, advanced composite repair, cabin refurbishment and component services, from its state-­‐of-­‐the-­‐art facility adjacent to Abu Dhabi International Airport.

Contact

Maik Dobberack
Marketing Manager
T: +49 30 208 482 638
E: [email protected]

Etihad Aviation Group
Duty Media Officer
T: +971 50 818 9596
E: [email protected]

Discover our 3D Printers

Opening a new dimension for Additive Manufacturing

E-Motorbike - Additive Manufacturing Applications

BigRep premieres innovative 3D­ printed prototypes for E‐Mobility and automation applications: showcasing a new dimension of additive manufacturing.

3D printing thought and innovation leader BigRep showcases the world’s first fully (FFF) 3D printed, functional E-Motorcycle and bionic passenger seat, as well as an adaptive robotic gripper and 360° mobile industry platform for automation applications.

Opening a new dimension for Additive Manufacturing, these prototypes designed by NOWLAB the BigRep innovation consultancy, and printed on BigRep’s large-scale 3D printers, include two groundbreaking prototypes for e-mobility applications: the world’s first fully 3D-printed and functional electric motorcycle, the NERA, and a bionic passenger seat, the Aero Seat. Advancing applications in AM are two other new prototypes, the Adaptive Robotic Gripper, designed for flexible handling applications, and the Omni Platform, a 360° mobile industry platform for fully automated manufacturing environments.

"These exciting prototypes not only demonstrate the unprecedented capacity of FFF large-scale 3D printing technology in Additive Manufacturing”, said Stephan Beyer, PhD, CEO of BigRep GmbH. "They also emphasize our unique ability as the market’s innovation and thought leader to bring cutting-edge technologies from design to reality, providing a market value added lead for our industrial customers.”

Discover our 3D Printers

NERA E-Motorcycle
Lead Design: Marco Mattia Cristofori with Maximilian Sedlak

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Using 3D printing technology for cutting-edge e-mobility solutions, NOWLAB has developed the world’s first fully (FFF) 3D-printed and functional e-motorcycle, the NERA e-motorcycle. As a distinction from similar prototypes, all NERA parts, excluding electrical components, have been 3D-printed, including tires, rims, frame, fork and seat.
"The NERA combines several innovations developed by NOWLAB, such as the airless tire, functional integration and embedded sensor technology”, explains Daniel Büning, Co-founder and Managing Director of NOWLAB. "This bike and our other prototypes push the limits of engineering creativity and will reshape AM technology as we know it.”

NERA illustrates the massive benefits that 3D printing offers for the production of end-use parts, particularly for batch sizes between lot size one to small series by reducing lead times and costs, optimizing supply chains, and limiting dependency on supplier networks.

In building NERA, the engineers didn’t simply adapt existing motorcycle designs, but instead envisioned a bike for large-format FFF technology, setting a benchmark for truly creative design; breaking the limits of traditional mechanical engineering. Among the many innovations featured in NERA are the airless tires with customized tread; a lightweight rhomboid wheel rim, flexible bumpers (instead of suspension) and the electric engine, which is fitted in a customizable case.

Aero Seat
Lead Design: Maximilian Sedlak

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Another prototype for an e-mobility application is NOWLAB’s Aero Seat, based on aerospace developments and game-changing passenger seat designs for autonomous driving technology. This exciting seat shell design has an almost bionic touch, look, and feel as the seat adapts to the driver’s individual body shape: using a 3D body scan prior to the seat production, the shell will provide its users with an unprecedented level of comfort to reduce the stress and physical discomfort of long-distance travel. Last but not least, flexible material (TPU) was used for printing the seat cushions, which molds to the passenger’s body shape. In addition, they are attached to the shell using only a few fixing points to reduce vibrations.

Adaptive Robotic Gripper
Lead Design: Tobias Storz

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The Adaptive Robotic Gripper has been designed to advance the full integration of robotics into automated AM, more specifically to grip finished parts from BigRep printers. Created on a BigRep STUDIO large-scale printer, the bionic gripper is mounted on a robotic arm. The gripper has three modular fingers and an opposable thumb and is capable of handling objects of any shape by wrapping its fingers around it instead of using excess force. It is responsive to pressure with a force-monitoring system that automatically adjusts its grip.
The bionic design of the robotic finger tips is inspired by the lamellae of geckos that help them climb walls. Each finger segment of the robotic gripper has an additional pad made of flexible lamellae. When force is applied these fine rib structures gently hold the gripped object by their restoring force.

Omni Platform
Lead Design: Marco Backenhaus with Mirek Claßen

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The equally innovative Omni Platform is a 360° mobile industry platform (size: 100 by 80 cm) for highly flexible applications in automated manufacturing environments and smart factories. It can both serve as an automated logistics carrier (loading capacity: up to 200 kg) and as a platform for additional devices such as robots, for example, to be mounted.

The 3D-printed platform has a fully integrated design, i.e. any bearings or electronics can be integrated during the printing process. Two key elements are special 3D-printed omni wheels with two different materials, allowing the platform to move sideways, and an integrated safety feature (human detection antenna), which was also 3D-printed.

Learn more about NOWLAB

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