User Stories Archives - BigRep Industrial 3D Printers

Xuberance Breaks the Mold with 3D Printed Furniture and Lifestyle Products

April 20, 2024April 18, 2024

Xuberance 3D printed furniture - hero image

Hailing from Beijing, China, Xuberance is a product design firm that leverages 3D printing technology to create unique furniture pieces and accessories. By embracing BigRep’s large-scale 3D printers, Xuberance is writing a new design narrative that combines sustainability and unparalleled design freedom.

From steam-bending woodworking techniques in the 19th Century to injection molded plastics in the 20th Century, advances in production technologies have continually reframed the creative possibilities. Product designers are looking to innovate and push the boundaries of their craft with cutting-edge technologies that allow them to support their vision.

In the 21st Century, design firms such as Xuberance are proving that there is scope for an entirely new conversation - one that empowers the unbound imagination of the product designer thanks to 3D printing technology.

Xuberance is making complex, intricate, and lightweight structures made possible by 3D printing objects from digital designs. The design ranges from furniture pieces to wearable fashion accessories and has become a symbol of a new age of digital expression.

The Form is More Than Function

With products such as the 3D printed Cloud Lamp, a luminaire that garnered the team the prestigious SaloneSatellite Award at the Milan Design Week in 2015, Xuberance has developed a distinctive design language; a language inextricably bound to the digital process of 3D printing.

The resulting intricate, organic forms of its 3D printed products are so unique, that they are virtually impossible to reproduce with conventional production methods such as molds.

Xuberance 3D printed furniture - BigRep 3d printed chair

“3D printing forms the backbone of our entire design and production process,” comments Leira Wang, Managing Director of Xuberance.

“Our designers can fully translate their digital designs into physical products using 3D printers such as BigRep’s. It offers unparalleled design freedom while pushing the boundaries of what’s technically possible.”

Large Scale Printing Creates Unique Design Possibilities

Although 3D printing was traditionally utilized by manufacturers to produce specific parts, Xuberance was one of the pioneers to embrace the medium as its primary tool to produce entire products from the ground up.

Having the ability to print larger single products such as chairs and stools with 3D printers such as BigRep’s ONE and STUDIO has enabled Xuberance to focus on building its product design niche.

The resulting products are not only strong, durable, and lightweight, but also unique in their form.

“Large-scale printing has had a transformative effect upon our overall ability to create distinctive designs,” continues Wang. “The BigRep large scale printers are instrumental in this, and unlock new possibilities by reducing time and costs.”

As evident with Xuberance products such as the Madame Butterfly chair - a single-piece 3D printed chair consisting of ethereal, organic, and intricately printed patterns, BigRep’s 3D printers allow the production of larger objects while retaining the intricate design.

“BigRep's dual extrusion printing offers a crushing advantage with its super accurate printing quality. We’re now able to faithfully translate our designer’s compositions into finished Xuberance products without losing any of the intricacies of the original design.”

says Wang.

Responding to Customer Demand

Unlike traditional manufacturing, where modifications require mold changes or adjustments to tooling, Xuberance has built its business around the flexibility of 3D printing, which allows for quick iterations to final product designs.

Not only has this allowed the team to eliminate the time and cost associated with physical adjustments in texture, structure, or color gradients can also be quickly executed depending on the customer’s requirements.

3D Printing in a Circular Economy

Product design and furniture industries have been plagued by non-sustainable practices, especially with nonbiodegradable plastics and other materials. But Xuberance is proving that 3D printed products have earned their place within the circular economy with their choice of materials.

With BigRep’s open material system, Xuberance can select the appropriate materials according to the requirements of each design, and set up printing parameters for each geometric model.

In addition to citing BigRep’s PRO HT and ASA filaments as exceptional with regards to their material composition and heat resistance qualities, Wang also highlighted the importance of their biodegradability in underlining the ethos of the company.

A Future Filled with 3D-Printed Possibilities

By embracing 3D printing technology, Xuberance has proven that it’s possible to create stunning, customized products whilst paving the way for a more sustainable future in design. Key to achieving this are the BigRep large format printers, which Wang believes are fundamental to achieving the company’s vision.

"There is an ancient Chinese saying," concludes Wang, "' When brothers are united in purpose, their strength can cut through metal.' We believe in the future of large-scale printing, and we will work together with BigRep to achieve this greater development."

As Xuberance continues to explore the unprecedented creative possibilities of 3D printing, its designers are forging a radical new language formed around the desire to celebrate form and organic beauty.

This approach echoes a historical truth: form isn't dictated by function, but rather, by the tools and technology available to the designer at any given time. With the tools of 3D printing at its disposal, Xuberance is at the very cusp of redefining the possibilities of product design.

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Find out how RH-Engineering and manoFigura design and create custom furnishings. Deep dive into their breakthrough product, the Magna Patero Ortus – a 3D-printed end-use sink.

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How businesses are manufacturing custom products with 3D printing
Why additive manufacturing is the perfect solution for custom and low-volume production
How large-format 3D printers unlock creativity and opportunity
Unique post-processing systems for end-use products

HOW RH-ENGINEERING & MANOFIGURA 3D PRINT LUXURY FURNITURE

About the author:

Patrick McCumiskey

Author

Patrick has over a decade’s worth of experience writing about design and technology. After first encountering 3D printing on a project while studying a Masters Degree in design, he’s taken a keen interest in the development of 3D printing and its impact on the world of design and tech.

3D Printing Accelerates Innovation in China’s Commercial Vehicle Industry

April 18, 2024March 28, 2024

China's commercial vehicle market accounts for over 40% of total global sales. Playing a key role in China’s success is the industry’s willingness to adopt new disruptive technologies like industrial 3D printing to pave the way for a new generation of production in custom commercial vehicle manufacturers such as CNHTC.

At the helm of this transformation is Dr. Dong, a visionary engineer, who established one of China’s largest 3D printing centers within CNHTC, the third-largest commercial vehicle manufacturer in the country.

With Chinese domestic demand for commercial vehicles projected to increase 10% year on year by 2028, Dr. Dong and his team could no longer exclusively rely on traditional manufacturing methods to meet the constantly evolving industry’s requirements.

Thanks to industrial 3D printing, the company has been able to advance prototyping and production processes for its heavy-duty trucks, haulage, and transport vehicles.

Embracing the Open 3D Printing System

Dr. Dong's approach to 3D printing is centered around being able to explore new applications and materials that are fundamental while innovating with the technology. While some of the 3D printer providers only sell closed material and software systems which limit application freedom, industrial 3D printers, like BigRep’s, are open for innovation. Being able to use any 3D print filament and software enabled CNHTC’s designers and engineers to leverage any technically compatible material.

It also helped CNHTC save costs as typically when companies are locked to the 3D printer provider’s materials, they’d have to forgo applications, outsource the print, or if the part warrants the investment, buy a new 3D printer that supports the material. CNHTC also had a better return on investment as they discovered the machine could be used for new applications with other materials.

Dr. Dong explains,

“Having an open-source 3D printer like the BigRep PRO is vital for our workflow. Open-source materials not only reduce production costs, they allow us to explore diverse material possibilities to achieve any number of desired outcomes”

Cost and Time Savings with Rapid Prototyping

CNHTC's traditional reliance on CNC machining and milling for prototyping translated to lengthy testing and iteration phases, often taking weeks. As a result, this slow process hurt the company’s ability to innovate within its design team.

“Since we’ve adopted 3D printing into our day-to-day work processes, we’ve witnessed a remarkable 50% reduction in both time and cost compared to traditional manufacturing methods for our projects to date.”

says Dr. Dong.

CNHTC 3D printed parts with the BigRep PRO

With the introduction of 3D printing, CNHTC’s workflow has undergone a total transformation. Now it takes just a few days, not weeks, for Dr. Dong and his team to turn digital designs into functional parts. "3D printing has enabled our designers and engineers to perform iterative optimizations with much faster turnaround times." Say Dr. Dong "While bypassing the mold-making stage entirely, we can directly 3D print structures that could not be created by the traditional processes.”

This kind of efficiency has allowed for the introduction of faster iteration and feedback cycles, ultimately allowing the design team to create products more in line with current market demands.

Large-Scale 3D Printing for Heavy-Duty Trucks

While previous generations and some of the current 3D printers have a smaller build limiting the size of the parts, Dr. Dong and his team have embraced industrial 3D printing with the BigRep PRO to produce large singular parts suitably sized for custom commercial trucks.

Following the same path as European commercial vehicle specialists like Zoeller Kipper, large 3D-printed parts such as customized panels and covers are being integrated as end-use components in CNHTC’s commercial trucks.

The BigRep PRO at the 3D printing CNHTC center

The high level of precision and dimensional accuracy in the large, robust prints meet CNHTC’s need for high-quality functional end-use parts. Printing sizable parts helps CNHTC eliminate the time-consuming and manual process of assembling smaller parts that might have errors in assembly.

He elaborates, "The quality of the larger printed parts makes it easy to integrate them directly into our vehicles. This not only increases production efficiency but also allows us to respond better to the demands of the market."

The Future of 3D Printing in Custom Commercial Vehicles

"What excites me most about the future is the possibility of using 3D printing to create more batches of end-use parts that can be directly used for manufacturing.” comments Dr. Dong.

The future of heavy duty vehicle customization with 3D printing for CNHTC

Confident in this blueprint for the future, Dr. Dong sees even greater potential for integrating 3D-printed parts directly into CNHTC’s production facilities. He concludes,

The application of 3D printing in commercial vehicles is one of the most significant technological events to have occurred in the automotive industry. The rules of the game have changed for the better, and we are using this to our full advantage

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About the author:

Patrick McCumiskey

Author

Symbiosis of Art and Technology Through Large-Format 3D Printing

March 28, 2024February 9, 2024

Large-format 3D printed art sculpture by Welly Fletcher

US contemporary artist Welly Fletcher builds a bridge to prehistoric cave art with a Large-Format 3D printed sculpture made with the BigRep ONE.

40,000 years ago, cave-dwelling Homo sapiens carved out a sculpture of a lion man into an ivory tusk using primitive chisels and tools.

The sculpture, which was discovered almost 100 years ago in a cave in south Germany, remains the earliest known example of Homo sapien art - and serves as a stark reminder of the extraordinary cognitive traits which have allowed our species to develop societies, religions, and technologies.

After experiencing the prehistoric sculpture in the Museum of Ulm in Germany firsthand, Albuquerque-based artist Welly Fletcher was inspired to create a sculpture for their latest exhibition SLANT at the Richard Levy Gallery in New Mexico. The sculpture explores the historic symbiosis of art, technology, and our species' kinship with animals.

Adding 3D Printing to the Palette

Fletcher’s sculptural centerpiece ‘Trans Time’, measuring 0.9 × 2.1 × 0.7 mts (36 × 86 × 28 inches), is an abstract depiction of a lion-like animal printed using the large-format BigRep ONE 3D printer.

Beginning as a clay model produced by the artist, the piece underwent a transformative journey as it was digitally scanned before emerging as a 3D printed object, made using the University of New Mexico’s Art Lab BigRep ONE 3D printer.

“The more I learned and experimented with the 3D printer, the more magical the results became. The printer gave both myself and my students the chance to understand the process behind translating analog techniques into digital.”

commented Fletcher, who teaches sculpture and digital technology at the University of New Mexico.

Trans Time, a large format 3D printed sculpture by Welly Fletcher printed on the BigRep ONE

Paying homage to the manner in which the original Lion Man sculpture is presented in the Museum of Ulm in Germany, Fletcher’s 3D printed animal head sculpture sits proudly upon an outline of a steel animal skeleton, which itself is fixed to a plasma-cut steel base.

While the orange-coloured sculpture is both visually and physically impressive in its proportions, Fletcher's deliberate choice of BigRep's PLA bioplastic aligned perfectly with the exhibition's theme of human-animal kinship and the body’s resistance to the environmental destruction of our species. Perhaps most significantly, the absence of carbon processes and toxic oils in PLA enhances the narrative of the artwork, further emphasizing our species' complicated relationship with the planet.

“When I started reading about the non-carbon-based processes of PLA, I was even more convinced of its ability to reinforce the environmental aspect of my work”

added Fletcher, who recently added the malleable bioplastic to her palette of materials.

Large-Format 3D Printing for Sizeable Sculptures

Trans-Time-a-3D-printed-sizeable-sculptures-by-Welly-Fletcher-at-the-exhibition-SLANT-at-the-Richard-Levy-Gallery-in-New-Mexico

Fletcher was also eager to highlight the practical benefits of incorporating the BigRep ONE printer into their artistic process.

Where traditionally, artists and their teams face numerous logistical hurdles in the transportation and in the assembly of separate heavy pieces; the BigRep ONE 3D printer enabled Fletcher to print the entire Trans Time sculpture as a unified whole, thus minimizing the complexity of production and assembly.

Describing the experience as transformative, Fletcher emphasized how the seamless printing of the entire sculpture marked a significant shift in their artistic process.

While the original cave sculpture stands as a testament to the imaginative prowess of early Homo sapiens, the primitive tools of that era made its production a complex and time-consuming task, with some estimates suggesting it could have taken a group of humans around 400 hours to complete.

Welly-Fletcher-and-her-sculpture-TRANS-TIME-at-her-exhitbition-SLANT-at-the-Richard-Levy-gallery

Thanks to BigRep ONE, however, contemporary artists now have the ability to effortlessly produce much larger and more complicated forms at the touch of a button - a sentiment that further underlines the enduring alchemy of the medium of sculpture.

“3D printing grants artists working with sculpture a significant advantage. It enables the creation of objects that simply aren't feasible by hand. Witnessing the final object materialize before your eyes has a magical quality to it.””

Fletcher elaborated.

Analog Roots in a Digital World

There’s a comforting circularity associated with Fletcher’s Trans Time sculpture. On one hand, its prehistoric connotations draw our attention to the elasticity of time and the prevalence of human creativity. On the other hand, we’re reminded of the powerful symbiosis between art and technology, and, ultimately, are left with an overwhelmingly positive impression of our species thanks to the sculpture’s use of eco-friendly materials.

With digital technologies such as 3D printing proving invaluable to the field of sculpture, Fletcher’s advice to artists wanting to incorporate 3D printing into their work is simple: let the process inform the results.

Want to Learn More About Large-Format 3D Printing Applications in Exhibitions?

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Unlimited Creativity in 3D Printed Exhibitions

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About the author:

Patrick McCumiskey

Author

3D Printing Powers Wind Turbine Research at TU Berlin

January 15, 2024January 12, 2024

On average, wind turbine blades are a massive 80 meters long. When it comes to reengineering these towering blades, no other technology offers the freedom, precision, and adaptability to scale parts quite like 3D printing. While replicating them in a university lab might be near impossible, a scaled prototype with 1 meter blades is very much in the wheelhouse of a large-build volume 3D printer. Here, researchers go big by starting small.

Based on 3D-printed rotor blades, TU Berlin offers a course - Wind Turbine Measurement Techniques that imparts skills to measure the performance of the blades at different operating points. The students learn how to gauge the speed of the wind while at the same time assess the power generated by the turbine. The course revolves around comparing the performance of a traditionally made, hand-carved, 2 meter wooden blade with a 3D-printed 1 meter rotor blade with the gyroid infill.

The additively manufactured blade is the fruit of the research conducted by a Ph.D. and a Master’s student of TU Berlin, Jörg Alber, and Laurin Assfalg , respectively. During the study, they discovered that with 3D printing, experimenting with different infills, shapes, and materials, the sky's the limit.

Laurin Assfalg:

"3d printing was a compelling option to produce the rotor blades as it can create complex forms and enhance performance. The idea was to come up with the science that can somehow be used for big rotor blades too."

3D Printing Breathes Life into the Blades

The research's objective was to find alternative ways to fabricate wind turbine rotor blades. By creating and optimizing rotor blades on a smaller scale with 3D printing, Jörg Alber and Laurin Assfalg sought to develop insights that could be useful for additively manufacturing life-sized full-scale rotor blades in the future.

The conventional way of creating wind turbine rotor blades is through subtractive methods such as hand-carved wood, computerized milling, or molding. These processes, although time tested and well established as the gold standard in the wind turbine industry, weren’t an ideal choice for the research as these blades don’t allow customizable complex structures needed for testing. Their decision to design and produce the 3D-printed blade was the technology’s ability to create more intricate forms and infills (the internal structure of a 3D-printed part) compared to traditional subtractive methods.

3D Pinted Wind Turbine Blades for TU Berlin Research

3D printing offered efficiency in printing the blades and could easily accommodate a wide range of shapes and structures that would eventually be subjected to rigorous testing. The size of rotor blades to be printed were 1 meter in length which made the large-format industrial BigRep ONE the perfect choice. The one-cubic-meter build volume BigRep ONE is designed to manufacture massive 3D prints for the most demanding and geometrically complex applications. Housed at the maker space of the TH Wildau, the BigRep ONE produced the blades in a single seamless print, the entirety of the blades was printed horizontally without any support in less than a day.

For the design, the blades were developed using freely available intelligent software and BigRep’s BLADE. The vital settings for the print like the printing direction, layer height, wall thickness, infill structure (gyroid), and infill density were easily customizable on the BLADE software. The open access principles 3D printing is based on were yet another reason that made additive manufacturing a compelling choice in the framework of a low-budget university project.

Structural Considerations: Infill and Material

The structural design of the wind turbine blades was based on both the study of different infill structures and 3D printing material.

1. Gyroid Infill

Components such as wind turbine blades often experience a constantly changing load because of aerodynamic and inertial forces during rotation. After extensive infill research, gyroid’s isotropic properties made them an obvious choice as they endure loads that constantly fluctuate.

The gyroid infill is made of a complex network of twisted and interconnected tubes forming a repeating pattern that extends infinitely in all directions without intersecting or overlapping. The result is a continuous lattice structure resulting in extraordinary stability at very low density which were the mainstays necessary for lightweight rotor blades. While designing this complex pattern manually might take ages, 3D printing software simplified the process automatically and implemented it in the rotor blades.

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

Apart from its strength, gyroid infill is also known for its material efficiency. Because of the interconnected channels, it reduces material usage without compromising structural integrity. This aspect was a huge advantage while printing the blades which might have otherwise ended up being heavy and consumed a substantial amount of material.

2. BigRep’s Industrial Grade PRO HT

The research team printed the rotor blades with PRO HT as it checked the boxes: easy to print, high strength, and has the ability to withstand high temperatures. The user-friendly filament doesn’t warp often and delivered aesthetic prints with a smooth matte finish.

The team also considered the ecological footprint of the blades, and the industrial grade PRO HT being a biopolymer, has a reduced environmental impact when compared to filaments derived from fossil fuels.

Putting the Blades to the Test

Testing the 3D-printed blades involved structural and wind tunnel tests to evaluate how they hold up under a range of parameters.

1. Structural Testing

The prototype rotor blades were exposed to the ULCs (Ultimate Load Cases) with the Universal Testing Machine (UTM) at HTW Berlin.

Ultimate Load Cases (ULCs) encompass extreme loads applied during testing, while a Universal Testing Machine (UTM) is the device used to simulate or apply ULCs in structural testing. The machine evaluates how materials behave under controlled forces or strains.

What are Ultimate Load Cases (ULCs)?

The conditions under which a material or structure experiences the maximum anticipated load, stress, or forces it might encounter in the real world. By subjecting materials to these ULCs, you can gather data on how they behave under stressors which helps in the design and validation of the rotor blades for safety and reliability.

What is a Universal Testing Machine?

A Universal Testing Machine (UTM) is a device used to test the mechanical properties of materials or parts, such as tensile strength, compression, bending, and hardness. It applies controlled forces to the subject to measure how it responds under different conditions, providing valuable data for material analysis and quality assurance.

The stress tests analyzed potential damages within the 3D-printed shell like buckling and cracks when it was under certain forces. The ultimate root bending moments (maximum bending forces experienced at the root section of the rotor blade) were tested with point forces (concentrated forces exerted at specific areas) at three blade positions and in both bending directions. The blades were also tested under an intense centrifugal force of Fmax = 3000 N by a heavy-duty crane.

Despite the rigorous and thorough structural testing, the blade remained unscathed, reverting to its original shape, with absolutely no signs of cracks or buckling.

2. Wind Tunnel Tests

Wind Tunnel for the 3d printed rotor blade tests

To help the researchers find insights into the rotor blade’s aerodynamic efficiency, structural stability, and whether the wind turbine could extract wind energy, the wind tunnel tests were crucial. The tests simulated and analyzed the wind turbine blades in controlled aerodynamic conditions within the large closed-loop wind tunnel at the HFI of the TU Berlin.

The wind turbine blades were designed to work best at a certain speed, but when they tested it, the researchers realized it worked better at a higher speed than what they had initially planned. Its maximum efficiency was at 5.4 times the speed of the wind, rather than the 4 times it was designed for. This was because the turbine was engineered based on natural wind flow, not the conditions inside the wind tunnel where it was tested.

The Future of Wind

The culmination of Laurin Assfalg and Jörg Alber’s research, the wind turbine with 1 meter 3D-printed rotor blades, currently resides at TU Berlin. It is the pillar of the course “Wind Turbine Measurement Techniques” and is a constant test subject for the experiments that determine what the future of harnessing wind energy might look like.

Apart from the enhanced performance of the 3D-printed blades, the study revealed other promising outcomes for the environment. The 3D-printed prototype blades produced for the Ph.D. thesis weren’t coated as part of the post-processing, so they can be easily recycled and upcycled. The research paves the way for further studies into enhancing the efficiency of wind turbines to harness clean, green, renewable wind energy.

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:

Natasha Mathew

Copywriter

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

Winds of Change for Vestas: 3D Printed Tooling Transforms Wind Turbines

January 8, 2024January 4, 2024

3D printed tooling for vestas windmills.jpg

There aren’t a lot of technologies that can propel towering wind turbines to new heights of time and cost efficiencies, but large-format additive manufacturing rose to the challenge and delivered with its eclectic range of applications.

Vestas, a global leader in sustainable energy solutions, designs, manufactures, installs, and services wind turbines across the globe. With more than 160 GW (billion watts) of wind turbines in 88 countries, the renewable energy giant has harvested more wind power than anyone else in the game.

When Vestas needed to replace the jigs and fixtures that help construct their wind turbines, BigRep’s large-format additive manufacturing system was tasked to produce the tooling they needed. The everyday wear and tear of industrial work on traditional metal jigs and fixtures could deform tooling in ways that cause faulty construction. The BigRep STUDIO produced resilient plastic tooling that performed flawlessly and soon Vestas found more applications for the machine than what they had initially invested in.

Ultra Precise Large-Scale Additive Tooling

Vestas' primary requirements were to create jigs and fixtures to position a vital component, the lightning protection system, within the wind turbine's blades. Accuracy is paramount because these blades endure constant inclement weather conditions and are highly susceptible to lightning strikes. The conventional approach is to use steel jigs and fixturing tools but they came with inherent limitations. These metal tools, although robust, faced challenges with deformation and undetectable damages.

lightening-protection-system-tooling-vestas

The plastic tooling, engineered through additive manufacturing, spelled remarkable advantages over its steel counterpart. Particularly, its lightweight properties, resistance to deformation, and unique ability to yield or break under stress. Fracturing under duress was paramount as these ensured faults were detectable early on which is critical in turbine assembly.

Transitioning from traditional steel tools to advanced polymer-based 3D-printed tooling was one of the highlights of this collaboration with BigRep. The modularity of the newly designed 3D-printed tool simplified Vestas' manufacturing processes, offering versatility to accommodate different configurations with a single adaptable design.

Vestas' tooling for the installation of the lightning protection system being 3D printed on the BigRep STUDIO.

The switch to 3D printed tooling led to significant improvements in both efficiency and cost reduction. Vestas observed a remarkable three-week reduction in lead time and an impressive 72% cost reduction in manufacturing these crucial components. The tooling proved to be highly precise, lightweight, and surpassed traditional manufacturing's accuracy standards by holding measurements down to a couple of microns.

The stability of High-Temp CF material used for the tools resists changes due to temperature and humidity fluctuations making them reliable. This in turn lowered costs, reduced carbon footprint, and eliminated additional transportation expenses associated with conventional manufacturing methods.

Jeremy Haight, Principal Engineer at Vestas:

"By having Additive Manufacturing in our pocket, we were able to flood the floor with quality tooling, by which we enable our regular production workers to do more of the important spot checks, which results in better quality."

Optimized Manufacturing Efficiency and Field Service Operations

The transition from physical to digital part inventory, enabled by 3D printing, delivered fundamental advantages for Vestas. Additive manufacturing excels in production on demand, small-scale production, and swift iterations in designs, resulting in reduced costs, streamlined logistics, and mitigated expenses linked to conventional manufacturing methods. Additionally, Vestas incorporated smart fixtures, integrating sensors and circuits into their 3D-printed tools to enhance functionality and accuracy.

Given the extensive global reach of Vestas' operations across continents, the challenges associated with lead times for spare parts and expedited costs further underscored the compelling nature of AM solutions. Aligned with Vestas' IoT strategy and Industry 4.0 initiatives, 3D printing bolstered supply chain agility—an essential factor, especially when relying on suppliers in distant countries.

This shift towards digital inventory not only eliminated tax burdens but also significantly enhanced the value of the manufacturing process. The reduced mean time to repair (MTTR) metric served as a marker for increased efficiency and reduced downtime in both manufacturing and field service operations.

3D Printing in Response to COVID

During the COVID-19 pandemic, Vestas produced over 5,000 personal protective devices with their BigRep STUDIO for frontline workers in healthcare facilities. They designed and produced AM face shields and door claws to help reduce the spread of infection and create safe, hygienic working conditions. The design was made open source which resulted in more than 1000 downloads.

Circularity and Sustainability

Vestas turns their scrap carbon fiber from the manufacturing process into additive manufacturing feedstock. With BigRep's open environment ecosystem, they can upcycle waste into 3D-printed parts and prolong the life of what would otherwise go to waste. The process repurposes and transforms carbon fiber into 3D printing material by grinding, compounding, and filament extrusion:

Grinding: The waste carbon fiber undergoes a grinding process to break it down into smaller particles. This grinding process reduces the carbon fiber scraps into finer granules, creating a more manageable form for further processing.
Compounding: The ground carbon fiber particles are then combined with a suitable thermoplastic matrix material. This compounding step involves mixing the carbon fiber granules with the thermoplastic polymer, often through methods like extrusion or compounding machines. This mixture forms a composite material, combining the properties of both the carbon fiber and the thermoplastic.
Extrusion: The compounded material is then heated and melted before pushing it through a nozzle to create a continuous filament of uniform diameter. This filament, now containing recycled carbon fiber, can be used as feedstock for 3D printing.

Apart from recycling its waste carbon fiber, Vestas also substantially minimized its carbon footprint by maintaining a digital inventory of components and printing them on demand with the BigRep STUDIO. Maintaining physical inventories of components and the logistical burden associated with transporting them across continents are no longer an issue as they are printed at the location required.

Reshaping Wind Energy

By replacing traditional steel tooling with resilient plastic counterparts crafted through additive manufacturing, Vestas advanced its manufacturing capabilities in wind turbine construction. What started as a project to create tools for blade assembly and QA, then extended to the production of spare parts, streamlined supply chains, and later supported COVID initiatives.

With 3D printing, Vestas aligned their production process with their vision: sustainable energy solutions powered by sustainable manufacturing practices.

Want to learn more about how Vestas leverages 3D printing for tooling?

Join Vestas’ Principal Engineer, Jeremy Haight, as he discusses the resounding success of implementing 3D printed tooling and moulds in the manufacturing of their renewable energy systems.

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Why 3D printed plastic tooling improved Vestas’ production quality
How in-house production helps to improve factory equipment on demand
Why manufacturing equipment is the “sweet spot” for 3D printed low-volume mass production
How hybrid 3D printing can bridge the gap for ultra-high-strength applications
The health and safety benefits of lightweight 3D printed parts

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HOW VESTAS MANUFACTURES WINDMILLS WITH 3D PRINTED JIGS AND FIXTURES

About the author:

Natasha Mathew

Copywriter

3D Printing Reinvents the Bass Drum Without Missing a Beat

January 5, 2024December 21, 2023

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

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

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

Defying Conventional Constraints

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

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

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

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

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

Dreaming BIG

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

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

He adds,

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

Anatomy of the 3D Printed 24-inch Bass Drum

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

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

He elaborates,

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

3D Printing Hits the Right Note

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

BigRep 3D printed drum Oliver Deeg in a recording studio

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

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

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

Oliver concludes.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

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

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

Explore the ONE

About the author:

Natasha Mathew

Copywriter

Leveraging 3D Printing for Automotive Customization at AVI Boston

November 3, 2023October 11, 2023

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

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

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

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

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

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

What the STUDIO 3D Printer Brought to the Table

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

STUDIO G2 features that MOVED the

needle for AVI BOSTON

Large Build Volume

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

Dual Extrusion

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

Reduced Post Processing

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

BigRep BVOH Water-Soluble Support Filament

Digital Inventory

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

Automotive Customization with 3D Printing

Complete auto interiors 3D printed, including panels, doors, cup holders, and more.

How AVI Benefited From BigRep’s STUDIO G2

Works Around The Clock

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

Complex Geometries And Fine Details Come Through

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

Automotive Customization with 3D Printed Car Parts

AVI Boston 3D prints custom car parts with the BigRep STUDIO G2.

Cost Effective Solution

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

Intuitive User Interface

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

AVI Boston employee examines a newly installed 3D printed door panel.

The BIG Advantage

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

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

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

DIGITIZING PRODUCTION OF CUSTOM LARGE-FORMAT AUTOMOTIVE PARTS

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

Explore the ONE

About the author:

Natasha Mathew

Copywriter

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

July 20, 2023July 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.

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

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

January 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.

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

Explore the ONE

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!

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Want to Learn More about 3D Printing for Emergency and Commercial Vehicles?

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Adding 3D Printing to the Palette

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3D Printing Breathes Life into the Blades

Structural Considerations: Infill and Material

1. Gyroid Infill

2. BigRep’s Industrial Grade PRO HT

Putting the Blades to the Test

1. Structural Testing

2. Wind Tunnel Tests

The Future of Wind

Want to Learn More About Gyroid Infill?

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Natasha Mathew

Ultra Precise Large-Scale Additive Tooling

Optimized Manufacturing Efficiency and Field Service Operations

3D Printing in Response to COVID

Circularity and Sustainability

Reshaping Wind Energy

Want to learn more about how Vestas leverages 3D printing for tooling?

About the author:

Natasha Mathew

Defying Conventional Constraints

Dreaming BIG

Anatomy of the 3D Printed 24-inch Bass Drum

3D Printing Hits the Right Note

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

About the author:

Natasha Mathew

What the STUDIO 3D Printer Brought to the Table

STUDIO G2 features that MOVED the

needle for AVI BOSTON

Large Build Volume

Dual Extrusion

Reduced Post Processing

Digital Inventory

How AVI Benefited From BigRep’s STUDIO G2

Works Around The Clock

Complex Geometries And Fine Details Come Through

Cost Effective Solution

Intuitive User Interface

The BIG Advantage

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

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

About the author:

Natasha Mathew

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?”

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

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