User Stories

AMAZEA Underwater Scooter, Serially-Produced with BigRep 3D Printers

For the first time ever a consumer water sports mobility device will be 75% additively manufactured (AM) with serial-produced, custom 3D-printed parts: The AMAZEA scooter’s body and front parts are being produced on three BigRep ONE large-format 3D printers using engineering-grade materials by BigRep, the global leader in large-scale 3D printing and additive solutions.

"AMAZEA is an industry-first breakthrough with the potential to redefine maritime vehicle technology and the consumer experience in water sports around the world,” said JAMADE Managing Partner Janko Duch, who founded the company together with Martin Oser and Detlef Klages in July 2018. “We opted for the BigRep ONE due to its cost efficiency, accuracy and quality when compared to the extremely high investment for traditional tools, particularly in the first year’s lower quantity,” the founders explained. German-based JAMADE is specialized in the development and manufacturing of e-powered water sports equipment for the end consumer market.

The large-format BigRep ONE 3D printer was key to a successful product launch, providing the high flexibility and speed AM offers, also making the development process much more time-efficient.

JAMADE started on white paper and progressed through product development. Offering a big 1m3 print volume, the BigRep ONE 3D printer provided unmatched cost efficiency, operational reliability and excellent technical qualities during JAMADE’s prototyping and the end-use parts’ serial production. The material is BigRep’s Pro HT, an easy-to-use filament designed for end-use applications. With a softening resistance of up to 115 °C, it offers a significant increase in temperature resistance (compared to average PLA), and minimal warping and shrinkage, which makes it perfectly suited for marine environments. As a material derived from organic compounds, Pro HT is biodegradable under the correct conditions, CO2 neutral and environmentally friendly.

“This scooter is a BigRep showcase of our digital solutions empowering production by leveraging the full potential of large-format 3D printers with high-performance filaments,” says BigRep Managing Director Martin Back. “It also signifies the rapid progress of 3D printing into the serial production of consumer end products, opening a new dimension for AM in similar niche but high-tech markets as well.”


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

The underwater scooter, which pulls the diver attached to it forward through the water, is an environmentally friendly, emission-free and low-noise method of exploring marine life without disrupting the eco-system. AMAZEA is an agile underwater scooter based on the “catamaran principle” and replicating a dolphin’s special body ergonomics that enable faster movement.

The stylish design offers a robust frame available in various bright colors. Thanks to an electric BI motor drive powered by two engines (3.1 KW each) and a rechargeable lithium-ion battery set up in the scooter’s front, the high-performance scooter offers a maximum speed of 20 km/h (underwater) or 30 km/h (gliding above water) and can be operated up to depths of 18 meters. Thanks to its light weight of just 25 kg (without battery) and a user-friendly control panel, handling is very easy.

3D printing offers real customization. Changes in size or shapes, and customer feedback or requests are able to go straight into the product. Large-format printing also ensures the scooter’s water-resistance: If the front or body were assembled using several smaller parts, openings would be a potential risk for leaks.

Large-format 3D printing enabled the quick turnaround and quality needed for this first of its kind water scooter.

Paravan’s Life-Changing Vehicle Customization with Large-Format AM

For some companies, a shift toward Industry 4.0 means scaling up to mass production of the same goods or near-identical lines of products. For other firms, industrial advancements present potential for greater customization and manufacturing bespoke products.

One such company is Paravan GmbH – a German company developing and supplying independent and autonomous vehicle drive systems. Paravan has been a leading international provider of vehicle customization for people with disabilities or special needs since 2005 as part of a wider mobility concept based around modifying vehicles, lifts, cartridge lifts and ramp systems.

Their solutions are specifically tailored to individual needs, incorporating features like wheelchair access, loading systems, rotating seating, and many more accessibility assets for safety and comfort. Paravan’s passion lies in providing personalized vehicle components that enable one of the most precious things there is: mobile freedom.


Find out more about how BigRep is changing vehicle
customization in our case study with Paravan GmbH
Read Now

 

3D Printing for Accessibility

“With the BigRep ONE, we can quickly and inexpensively print complex components that are either impossible or very difficult to produce by machine,” said Mario Kütt, Head of Mechanical Construction at Paravan. “Now we print a component that we had previously milled, thereby saving around 75% of the costs.”

Paravan uses a BigRep ONE 3D printer to produce end-use parts for its road-approved, safety-related industrial applications, including its first prototype for a revolutionary new steering mechanism. Unlike most cars, this Paravan steering wheel is electronic instead of directly connected to the steering column.

“Together with a 3D scanner our construction engineers work with [the BigRep 3D printer] daily,” said Paravan’s Alexander Nerz. “Of course, it’s great to be able to quickly and efficiently build designs overnight. To be able to install the piece into the customer’s vehicle the very next day. It’s a really great tool.”

The nature of Paravan’s customized vehicle business means the ability to do rapid large-format prototyping is vital. With just a clean CAD file, Paravan’s engineers can design functional parts specific to a user’s needs and often produce a printed part within one day. Custom-fitting vehicles becomes a cost-efficient, fast process. “We have more pieces that are new than those that we have had for a long time,” says Mr. Kütt, who produces at least two prototypes per week using the BigRep ONE.

For customers who have difficulty grasping the controls with their hands, for example, Paravan has been developing custom grips that enable drivers to keep a steadier hold on the gear stick or steering mechanism. They take a mold of the individual’s hand grip and create a custom grip with flexible, material for simplified handling. Using a 3D scanner, they convert a 3D scan of the final model into a CAD file. After refining the design, they are ready to print the prototype on the BigRep ONE.

The Right Materials for Innovation

As the printed parts are often end-use, placed directly into Paravan’s custom vehicles, post-processing their prints is an important part of Paravan’s process. “Currently we are only using PRO HT filament for production,” said Mr. Kütt. “Mainly for its high temperature resistance, which is necessary for the vehicles, especially in summer.”

Rather than painting the pieces smooth, which Paravan finds can be time consuming, they prefer to lightly sand the printed parts and prime them, creating the finish.

Visit BigRep's Online Shop to find out more about our catalogue
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As Paravan continues to innovate in the automotive industry, BigRep’s 3D printing technology will support the company to explore the potential of autonomous driving.

For businesses on the cutting edge of automotive technologies, being able to swiftly design and print prototypes allows them to remain frontrunners in their fields and provide, particularly in Paravan’s case, life-changing products and services to customers.

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]

The GENESIS Eco Screen – How BigRep is making cities greener with 3D printed urban ecosystems

BigRep’s latest innovation is tackling some of the world’s biggest environmental challenges. Plastic recycling, wasted water, and rapidly deteriorating biodiversity in urban settings are being fought with a groundbreaking prototype in urban architecture: the GENESIS Eco Screen.

The GENESIS, a fully 3D printed urban biodiversity habitat, was designed by Lindsay Lawson, an Applications Specialist at NOWLAB, BigRep’s innovation consultancy. The GENESIS Eco Screen takes advantage of solar radiation analysis for agent-based modeling and parametric design to create a computer-generated final product with unique characteristics specific to its environment. The design process ensures that each GENESIS iteration has ideal placement for its plants, insect habitats, and embedded channels for water flow and drainage for the setting it will be installed in.

Measuring an impressive 4 by 4 meters, the GENESIS Eco Screen is printed with BigRep PETG filament and BASF Innofil3D rPET made of 100% recycled PET on four large-format BigRep ONE printers. It is installed in Berlin, Germany at Invalidenstraße 86 where Germany’s Federal Center of Excellence for the Cultural and Creative Industries (Kompetenzzentrum Kultur- und Kreativwirtschaft) hosted Fiction Forum on behalf of the Federal Ministry for Economic Affairs and Energy.

Fiction-Forum001

Created to demonstrate the environmental opportunities presented by additive manufacturing technology, the GENESIS highlights circular economy solutions to abundant plastic waste. Aimed at minimizing waste by closing the gap between resource input, waste, emissions and energy usage, circular economy is an important concept to reduce raw material consumption and divert useful materials from landfills. At Fiction Forum, where the GENESIS was printed live throughout August in Thaersaal, the active BigRep ONE printers were displayed with a Dual Axel Shredder, designed by Raw Paradise, to underscore the 100% recycled rPET filament being used and the potential for additive projects made using common PET waste.

Daniel Büning, a fellow of the Kompetenzzentrum and NOWLAB’s Managing Director, lauded the innovation saying, “disruptive technologies such as 3D printing are key to solving some of the world’s biggest problems. The GENESIS Eco Screen shows how society can develop a greener future – with circular economy solutions that are sustainable, local, modular and collaborative.”

Find out about the incredible large-format filaments
that make NOWLAB's innovations possible.

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The GENESIS ECO SCREEN at a glance:
Dimensions: 4000 x 4000 x 300 mm, made of 16 segments
Materials: BigRep PETG and Innofil3D recycled rPET
Team: Daniel Büning, BigRep CIO and NOWLAB Co-Founder
Project Lead: Lindsay Lawson

Find out more about the BigRep ONE

Personalized Fingerprint Stool, Custom Manufacturing with BigRep

Additive manufacturing has offered ungated access to affordable manufacturing solutions and unprecedented reductions in the cost of low-volume high-mix manufacturing. Because of these combined possibilities, a wealth of personalized products have become available to the market from all sizes of businesses.

The affordability of large-format additive technology has even changed the way professionals are introduced to manufacturing processes, which now often begins during post-secondary education with in-house industrial 3D printers. Universities everywhere are integrating additive into their curriculums in a variety of disciplines that allow students to have hands-on experience with manufacturing technology before entering the workforce.

After Australia’s University of Technology Sydney (UTS) acquired a BigRep ONE large-format 3D printer for their fabrication lab, ProtoSpace, they were eager to flex their new additive muscles and create a publishable case study. The task was taken on by Dr James Novak, at the time a postdoctoral researcher at UTS (now a Research Fellow in additive manufacturing at Deakin University) who set out to create a showcase-worthy design that would test the BigRep ONE’s capabilities and highlight its potential to produce highly customizable products.

Learn how prominent universities are integrating additive in our
guide to Large-Format 3D Printers For Education and Research

Read the Guide

Figure 2

Novak took personalization to the next level in his design, literally incorporating himself into the project by creating a stool from he and his wife’s fingerprints.

“It was designed when my wife and I got engaged and features the ring fingerprint impressions from both of us,” said Novak. He noted the project was conceived in part because of the absolute individuality of a fingerprint, highlighting the unmatched level of personalization that additive manufacturing offers.

The highly-organic design connects the fingerprint ridges, weaving support through empty space before merging in the design’s open mid-section.

Novak explained, “as the fingerprints merge through the center of the design, an organic form emerges that can only be manufactured using 3D printing, and there is no support material needed.”

edf

To simplify the printing process, it was decided to print the design with a support raft that ensured the first layers – which are otherwise unconnected – wouldn’t warp, but Novak noted that the same result could be accomplished with the right build platform adhesive.

The resulting design is an excellent example of the unique capabilities of 3D printing: an entirely personalized end-use product with a complex geometry that can only be produced with large-format additive manufacturing.

Novak’s stool is also demonstrative of large-format additive’s unmatched potential for lean manufacturing, allowing for the creation of highly customizable products in small batch production. Combined with accessible price points and transferable design skills, large-format additive clearly presents an enviable solution at all levels of business.

Novak

Using only a small portion of the BigRep ONE’s build volume, multiple independent designs like Novak’s stool can be easily completed in the same production run, and production speed can be easily increased by taking advantage of large-format’s scalability – adding to existing machines by opting for performance enhancements like a second extruder to run in tandem.

With this unparalleled flexibility and potential for customization, large-format additive presents an accessible, future-ready manufacturing solution.

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

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

Explore the ONE

LARGE-SCALE INNOVATION. LIMITLESS CREATIVITY.

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

Explore the ONE

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.”


Find out what large-format 3D printing can do for you
in our free Guide to Integrate Large-Format!
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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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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]

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
case study with Ford Motor Company:
Read Now

 

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]

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To the Moon and Back with Bigrep on the set of the First Man Movie

first man movie and the Bigrep ONE

In 1969, Neil Armstrong became the first man to land on the moon, saying “that's one small step for man, one giant leap for mankind.” It was a historic moment, that would forever change our perspective on what is possible with new technology.

The First Man, directed by Damien Chazelle, is showing in movie theaters around the world and we can proudly say that Bigrep took a small part in its production. It’s unlikely that Bigrep will be the next Ryan Gosling or Claire Foy, but who knows, given how quickly artificial intelligence is developing.

“With new slicing software you can take a big scale model, chop it up and print it overnight on 18 3D printers. We literally ran those printers 24 hours a day for six months. This German company called BigRep developed a metre-by-metre print bed and they loaned us two of their machines so we could print an Apollo 11 capsule in one go,” said Nathan Crowley, the Production Designer for the film to the animationmagazine.net.

For Crowley, the four-time Academy Award nominee, it was important to have the real parts during the production process, to get a proper impression of their form on the set. Recording these key scenes using miniatures made it look more realistic, for the whole audience. Crowley believes in combining additive technology with old techniques. The results can be seen on big screens around the world. So what was actually printed? Well, the answer is not so obvious.

Remember the Saturn V rocket from the trailer? We are the only company capable of producing objects this size. The model was 3D printed on two Bigrep ONE printers! In addition to the rocket, the Apollo Command/Service Module and Lunar Excursion Module were also 3D printed. Amazingly, it is impossible to see the difference between the 3D printed objects and the ones created with traditional computer graphic techniques. Crowley and his team know how to blend both techniques, so the viewer cannot spot the difference. (To be honest, if the movie crew didn’t tell us, we would also be in the dark.)

From automobile parts for BMW to Hollywood movie sets, what’s next for additive manufacturing? Without a crystal ball, we can’t say for sure, but what we do know is that’s one small step for the movie industry, one giant leap for Bigrep!

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From 3D Scanning to 3D Printing – Finding 3D Solutions in Florida

3d scanning - Neometrix 3D solutions

When it comes to finding an individual solution for various Floridian industries, NeoMetrix is a go-to name, providing 3D scanning and engineering services. Surrounded by around 19,000 manufacturing companies, they have found a way to stand out in this sunshine state. Being active in a handful of major industries and knowing how important it is to understand the specific needs of their customers, they were bound to be a great fit for the BigRep reseller network.

It has been 15 years since Dan Perreault launched NeoMetrix Technologies, Inc. As the President & CEO of this Orlando-based company, he started out as a reseller of one of the world’s leading producers of 3D scanners and providing engineering services.  His experienced team offers a range of services and supplies from scanning and tooling to prototyping and designing.

DISCOVER OUR INDUSTRIAL USE CASES

Perreault describes the company as a solution-oriented organization. “We don’t want to sell boxes, we want to offer real solutions to companies,” he said. In terms of improving their productivity, the BigRep printer gives them not only larger format prints, but also reduced costs of materials, compared with other filament providers. For NeoMetrix, the BigRep STUDIO has turned out to be the perfect tool for expanding their cooperation with customers. “With BigRep,” Perreault continued, “the overall cost of machine ownership is much lower than competitive systems.   It’s our position that this attribute will allow more customers to take advantage of this technology.”

3d scanning of a statue

Florida is an ideal environment for working in the 3D printing industry, thanks to the broad array of industries operating out of the southern state. Perreault said, “Thinking of Florida you think… theme parks!” Indeed, this magical place opens many windows for large-scale 3D printing. “We definitely have a lot of opportunities in the entertainment industry. There is also a large aerospace presence here too.” In addition to that, NeoMetrix is active in the automotive, manufacturing and education fields, and have a wealth of experience working on projects for art and sculpture-making using 3D scanning and printing technologies.

The importance of having the knowledge and experience in the 3D scanning industry cannot be understated – it has helped make NeoMetrix one of the 3D leaders in Florida. It’s not only their excellent service in a diverse range of fields that makes them unique in the market, but also the customer-focused attitude they have. The depth of understanding their customers’ values and demands has put them in the perfect position to demonstrate the business benefits that come from large-scale 3D printing.

“We want to understand what it is customers want to do, how are they doing it now, and how we can help them do it better – and perhaps the BigRep way.”

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Driving 3D Printing into Future Factories: BMW Group Personal Mover Concept

Personal Mover Concept by BMW research center

As a result of improving technology, our world and our everyday lives are going through drastic changes, particularly in regard to mobility. We can drive, we can fly, we can cruise and we can innovate – we’re moving in completely different ways according to our shifting needs.

bmw1

To make the working lives of their employees easier and more efficient, renowned global automaker BMW Group has created the Personal Mover Concept. BMW Group Research and Innovation Center in Munich designed this impressive electric one-person means of transport. The idea behind such a unique project was simple:

Employees at BMW Group plants and logistics centers sometimes cover up to 12 kilometers per day on foot – and having to carry small parts and work materials often makes it even harder. Sites such as the BMW Group Research and Innovation Center in Munich or the BMW Group plants in Dingolfing and Spartanburg are sprawling campuses, where many employees have to cover huge distances to do their jobs. (source)

The thought was, why not sort a solution for that? Or, to take one step further, why not use additive manufacturing technology to print a solution?The Personal Mover Concept is 60 cm wide and 80 cm long, so even with one person on board, there is still a space for long or heavy objects. It can reach speeds of up to 25 km/h and turn on the spot to the left or right up to 90°. The handlebar contains the entire electrical system, the battery and the drive wheel. Having in mind the safety of users and pedestrians, the Personal Mover Concept includes a bell, brake and a dead man’s control. One of the most innovative facts about this object is that the handlebar stand has been 3D-printed on the BigRep ONE. As Richard Kamissek, Head of the Operations Central Aftersales Logistics Network department said, “It had to be flexible, easy to maneuver, zippy, electric, extremely agile and tilt-proof – and, at the same time, suitable for carrying objects. The Personal Mover Concept can do all of this – and is also fun to drive. We hope to start using it as soon as possible!”

BMW Plant Commuter

Being a part of this innovative idea is not only making us proud, but also giving us food for thought. If, thanks to 3D printing technology, mobility advancements are helping us improve the automotive, aerospace and electric vehicle industries, are there any limits for how far transport can go? Large-scale 3D printing can truly change the way companies innovate. We see everything from prototyping to the whole production process, where 3D-printed objects are present in everyday life and being used all over the world. Starting with factories, we expect to see these kinds of mobility tools in use at airports, shopping malls or warehouses.

3D printing can improve our environment in faster, more cost-efficient and creative ways. That makes it the ideal technology for supporting the mobility innovations and creates a range of the excellent opportunities for various industries. We were thrilled to learn of this smart project, and we cannot wait to see what tomorrow will bring for the 3D printing industry, BMW Group and for the entire network of BigRep customers and partners.

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