Digital Solutions Empowering Production: BigRep Showcases Industrial AM’s Powerful Applications at Formnext 2019

Berlin/Frankfurt am Main, 19 November 2019 - BigRep, the global leader in large-scale 3D printing and additive solutions, today at formnext, the world's leading exhibition for additive manufacturing, unveiled a fully 3D printed, autonomous electric podcar, LOCI. The groundbreaking design prototype presented is an exciting showcase for a whole range of industrial applications in Additive Manufacturing (AM) today – from rapid prototyping and design to functional end-use transportation created by large-format 3D printers with engineering-grade materials.

LOCI: The 3D-printed evolution of personalized, sustainable mobility

Taking center stage at formnext, the LOCI prototype is a fully 3D printed autonomous electric podcar, specifically designed as a “last mile transportation solution” in urban environments: airport and train station departures, daily work commutes, campus transport, and local deliveries. LOCI has been envisioned and designed by NOWLAB, the innovation consultancy at BigRep.

“LOCI is more than a vehicle, it’s the evolution of personalized mobility,” said NOWLAB co-founder and BigRep CIO Daniel Buening. “LOCI is an affordable solution for urban transportation, harnessing the agility of AM while also demonstrating the cost-efficient advantages of 3D printing for sustainable AM such as manufacturing personalized products on-site and on-demand.”

Thanks to the flexibility of Additive Manufacturing, unique prototypes or small batches of LOCI can be locally produced on demand without added costs, supplier dependence or long lead times. This eliminates the need for large warehouses and remote production facilities while simplifying logistics and reducing transport. All of this leads to a more sustainable AM production process. Production volumes can be easily upscaled with a fleet of BigRep printers.

Developed using parametric modeling, LOCI utilizes the full potential of AM and its limitless flexibility. The podcar’s design can be easily customized for a given location or application; adjusting handling purpose, materials, structural properties, special tires for different terrains, custom branding, and integrated solar power.

BigRep at Formnext 2019

In fact, the formnext showcase captures three different LOCI iterations: The Berlin LOCI model presented is a single-person campus commuter with a sleek design, touch screen media display, surround sound audio, wireless phone/device charging, integrated LED lighting, TPU airless tires, and embedded BigRep Part DNA technology. The San Francisco LOCI is a render concept version for urban commuting. Its narrow body can maneuver in traffic, a single right-side door lifts up to cover exiting passengers from rain, and it has two passenger seats. Finally, the Dubai LOCI is a render concept version for airport transportation with a high-end luxury feel, solar panels, space for luggage, and rugged tires for desert weather.

LOCI’s BigRep Part DNA™ technology is based on NFC chips embedded into the 3D printed parts. This chip can be scanned using a mobile device to identify the part. In the future it can be additionally integrated with sensors to monitor part status and provide maintenance or replacement information – simply scan the part and print a replacement.

Built with just 14 unique parts, LOCI measures 85cm x 146cm x 285cm, with the largest part measuring 1000 x 600 x 700 mm. All parts were printed with a BigRep PRO, BigRep Studio G2, or BigRep ONE additive system. The pod showcases the possibilities of 3D printing and engineering-grade filaments for industrial manufacturing: The body was printed with BigRep’s PRO HT, for the airless tires designers opted for TPU, the bumpers were created with PLX, and beams and joints with PA6/66.

Industrial 3D-printed prototypes: Making manufacturing more efficient

In addition to LOCI, BigRep will also present a set of fully 3D-printed prototypes for industrial applications, developed by NOWLAB in cooperation with its industry partners and presenting cost- and time-efficient innovations for Industry 4.0 manufacturing.

The factory of the future requires great flexibility to manufacture customized products and small batches. The NEXT AGV (autonomous guided vehicle), an autonomous transport system, developed by BigRep and Bosch Rexroth, are integral to agile, smart production. Contrary to traditional sheet metal molding, the 3D printed Next AGV is manufactured much more efficiently. The base framework of core elements (battery and electronics)  are enclosed in a 3D-printed shell that can be easily adapted for flexible industrial applications. Powered by an inductive energy unit running on a power grid, the NEXT AGV can serve as an automated logistics carrier with a load capacity of up to 250 kg. Tools and additional devices such as robots can be mounted onto the platform.

Other key elements of the NEXT AGV are special 3D-printed wheels with two different materials, allowing the platform to perform sideways movements, and an integrated safety feature (Human Detection Antenna), which has also been 3D-printed.

Another BigRep prototype is the AIRBUS Investment Shipping Case, a fully 3D-printed solution for delicate equipment transportation. High-quality cases must be certified to transport sensitive equipment, such as aerospace imaging cameras, when they break down or otherwise require maintenance. Traditionally, these are individually manufactured by hand at only a few sites around the world, making their availability and delivery an issue threatening quality and workflow: As a result, wait lists for the containers often exceed two years. BigRep created their solution by designing a template that uses a data-driven process to quickly generate the final, unique design of each container on demand. The cases take advantage of the versatile, dynamic qualities of BigRep’s TPU filament, an engineering- grade material that is firm when printed in a thick wall but soft and flexible in thinner compositions – making it highly shock-absorbent. It also enabled a design that can be manufactured as a single piece in an automated process. As a result, the full design and manufacturing process can be reduced to just 60 hours, greatly optimizing the supply chain.

Saving costs: Retrofitted airline seat becomes 3D-printed high-tech comfort

A game-changing prototype presented is BigRep’s Retro Seat, an original airline seat frame that has been refurbished with AM at NOWLAB and developed in collaboration with Dassault Systèmes, using their 3DEXPERIENCE platform and the industry solution experience “Passenger Experience.” The Retro Seat is 50 percent lighter than a traditional airline seat, creating huge benefits for sustainable aircraft engineering and operational costs. The prototype has a fully integrated design, i.e. any bearings or desired electronics, such as inductive charging for wireless smart phone charging, can be integrated during the printing process. The back of the seat’s headrest is equipped with both a “Bring your own device” outlet for tablets or other devices and multiple USB ports for passenger convenience. Additionally, the seat offers embedded blue LED light panels for setting the right mood during night flights and the arm rest is equipped with a smart cabinet solution to safely store laptops during take off and landing.

For more information on BigRep’s debut of new products and technologies, please visit its formnext booth (hall 12.1 / C121, Nov. 19-22)

LOCI at a glance

Technical Specs:

  • Overall Dimensions: 85cm x 146cm x 285cm
  • Number of parts: 14 main parts with additional inserts
  • Largest part: 1000 x 600 x 700 mm
  • Printed with BigRep PRO, BigRep Studio G2, BigRep ONE

Print Materials: Body: PRO HT / Tires: TPU / Bumpers: PLX / Beams and Joints: PA6/66

Additional Features:

  • Electric power / Touch screen media display
  • Surround sound audio / Wireless phone/device charging / LED lighting / TPU airless tires
  • BigRep Part DNA™ technology

Team Credits:

Co-Founder NOWLAB, BigRep CIO: Daniel Buening
Lead Designer: Marco Mattia Cristofori
Design Team: Mirek Claßen, Lindsay Lawson, Tobias Storz, Angelo Vannicola, Marco Backenhaus
Marketing and Creative: Amir Fattal
San Francisco and Dubai Concept Design: Marco Traverso

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]

Global Additive Applications Summit (GAAS) 2019

The 2019 Global Additive Applications Summit, held in Berlin and organized by RedCabin Events, was the first of a new interactive additive conference with a unique focus on applications and adoption. This first holding of the annual event featured a variety of industry leaders with impressive new additive applications – both conceptual and immediately adoptable.

“RedCabin did an amazing job organizing the event. Their unique, highly interactive conference style focused on networking and hands-on workshops was much more impactful than traditionally organized conferences,” BigRep’s CIO, Daniel Büning lauded. “In a way, their agenda mirrored the additive advancements that were presented, which promise so be so much more impactful if they can break away from simply filling in for traditional workflows.”

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Presentations addressed recent advancements in additive technology that have helped to realize previously developed concepts and presented brand-new contemporary applications that will continue additive’s upward trend of industrial adoption. Overall speakers confirmed that there is increasingly incredible, immediately applicable, value from additive technology left unapplied by many would-be industrial users.

Siemens’ Ulli Klenk discussed additive’s growing roll in the energy sector, specifically in the form of gas turbines. Siemens has managed to design a gas turbine for power generation that is fully 3D printable using metal additive systems. A now proven end-use application in a highly demanding industrial process, the use case is demonstrative of the incredible adaptability of additive technology. The application also takes advantage of additive’s ability to leverage local manufacturing for cost savings; by enabling in-house part production on demand, Siemens eliminates the need for spare part storage.


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From Ottobock, Thomas Stitz presented functional 3D printed orthotics. With exoskeleton designs, Ottobock has developed personal mobility orthotics that successfully enable disabled persons to walk. Additive manufacturing is an integral part of the process, leveraging body scanning and 3D printing to create the orthotics with perfect fit – an integral quality for long-term orthotics.

Representing Deutsche Bahn, Stefanie Brickwede, Managing Director of Mobility Goes Additive, discussed the use of additively manufactured end-use spare parts in Deutsche Bahn trains. The application here has seen massive savings in storage and the acquisition of parts that are no longer manufactured in traditional processes. To bring this application to the next level, Brickwede discussed ongoing development efforts of flame-retardant polymer materials that would enable Deutsche Bahn and other public transportation companies to meet the legal standards required to affordably print spare parts that come into passenger contact.

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Developing technology to test the feasibility of all these applications is Dr. Sven Lammers, head of Dassault Systems’ 3DEXPERIENCE Center in Hamburg, and Jörg Schnorr, Senior Project Manager of Automotive 3D Printing for BASF. The technology demonstrated by Dr. Lammers is an advanced additive simulation software designed to improve print validation, the generative design process, and end-use part integrity in their given applications. BASF and Shnorr’s similar technology focuses specifically on the simulation and validation of parts in an automotive context.

“We learned a lot about what it will still take to meet the challenge of serial industrial production in large quantity with additive technology,” said Martin Back, BigRep’s Managing Director. He added that “change management” endeavors aimed at seeing additive technology taught and adopted for radical innovation instead of gradual adoption – that only mimics traditional applications and workflows – is necessary for 3D printing technology to reach its true potential and increase its rate of adoption. “Copying non additive parts and printing them with AM doesn’t make sense,” Back said. “We need redesign for additive manufacturing, and conferences like GAAS are vital to guide industrial users in that change.”

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]

GAAS, A Hands-On Additive Conference for Industrial Applications

As a leader in industrial additive manufacturing solutions, BigRep is invested in growing processes, materials and applications and their effective implementation to push modern manufacturing forward. That’s why we’ve partnered with RedCabin Events to host a unique meeting of additive manufacturing experts.

On October 30th and 31st the new, exclusive Global Additive Applications Summit (GAAS) will run. A gathering of selected executives and innovative thought leaders over 2 days of detailed workshops and panels in an intimate Berlin location.

We decided to work with RedCabin because of the unique, exclusive, hands-on style of event they organize. We believe that in a field as functional as additive manufacturing, attendees should be bringing home more than thought leadership – they should take away new techniques and workflows to change the way they work with additive technology.

During this two-day Global Additive Application Summit, keynotes will be given from experts in the automotive, railway and aviation industries such as Ford, Bombardier and Airbus explaining their advanced applications and techniques for additive technology. Attendees will have a one-of-a-kind experience as the conference is blended with hands-on workshops guided by thought leaders for unmatched learnings.


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The event’s keynotes and panel discussions will be followed with attendees organized into small participatory groups for rotating workshops, formulated to gain deep insights into additive processes and experience a user perspective. With networking events spread throughout the two-day conference, attendees can be sure they’ll leave the event with enhanced knowledge and meaningful industry connections.

As an incredibly dynamic field that has dramatically evolved in recent years, additive manufacturing has enabled the fast, inexpensive prototyping for highly cost-efficient product development to inexpensively test enable the production of high-strength, light-weight components with geometries that were not previously achievable. Today, additive technology is evolving again from a prototyping focus to the production of end-use parts and will continue to grow into an accessible serial production technology.

Visit www.global-additive.com now to view the event’s agenda and reserve your spot.

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]

We saw you at RAPID+TCT 2019

This year at RAPID+TCT, North America’s most influential additive manufacturing event, BigRep contributed to the industry’s ever-growing momentum by announcing a new and improved  additive workhorse. The introduction of BigRep’s new generation STUDIO G2 large-format 3D printer was met with enthusiasm. We heard from industry leaders just how exciting an accessible large-format printer capable of producing finely finished parts with engineering-grade materials is. If you missed the chance to see the STUDIO G2 live, take a look at our article introducing the Studio G2.

The highly anticipated BigRep PRO was also on the floor, displayed for the second time ever in North America. The PRO’s massive size, fully enclosed with a one cubic-meter build volume, astounding speed, precision, and engineering-grade materials demonstrated the impressive capabilities of BigRep’s brand new Metering Extruder Technology (MXT®). We were happy to announce that beta units are already being installed at some of BigRep’s trusted partners, like New York’s Boyce Technologies, Inc.

“At this year's RAPID+TCT we were excited to show how BigRep continues to redefine additive,” said Frank Marangell, President of BigRep America, Inc. “It's not easy to do large-format, but BigRep has solved a lot of past challenges that limited the technology. Now we’ve unlocked the size, speed, accuracy, and repeatability in additive that industrial users need.”

STUDIOG2-RAPID

Marangell complimented the impressive knowledge from attendees at this year’s event, suggesting it may be a result of the continued adoption of 3D printing at the industrial level as access to engineering-grade materials within additive increases.

“BigRep has been an active participant in the industry’s growth,” he added. “The technology we presented at RAPID+TCT, the BigRep PRO and STUDIO G2, align to create industrial additive solutions for any business. They show how BigRep has moved on to the next industry challenge – enabling speed and precision with the engineering-grade materials that users demand.”

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The NERA, BigRep’s fully 3D printed eBike, also appeared at the event, presented for the first time ever in North America. It was accompanied by the vehicle’s designer, BigRep’s own Marco Mattia Cristofori, who was present to answer questions about the NERA’s design and how industry leaders can similarly harness the power of large-format 3D printing to create futuristic achievements.

"The NERA is made to be an inspiration for the automotive industry," Cristofori said, "We made it to open the industry's eyes to the potential of additive manufacturing today. It shows how processes are ripe for re-thinking with a totally new perspective. With today's additive technology we can make yesterday's impossible a reality in a faster, more sustainable and customizable way."

Marco-NERA-Students

Cristofori took the stage during the conference’s applications track to share some insight into designing the NERA eBike and other challenging projects taken on by the innovation and consultancy department of BigRep’s NOWLAB that defy many of the assumed limitations of 3D printing. The NERA is just one example of revolutionary applications that companies at the forefront of their industries are capable of with large-format additive manufacturing at their disposal.

With the new wealth of 3D printing knowledge at the event came an innate understanding of the need for large-format additive and sights set beyond prototyping. Attendees were well informed that additive technology has evolved beyond initial prototyping applications and is now boasting new capabilities in producing end-use parts, and facility tooling by creating jigs and fixtures.

Here at BigRep we’re thrilled to have been a part of the prestigious happenings at RAPID+TCT and are proud to hear that our big innovations are meeting the industry’s growing needs.

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

About BigRep:

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

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

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

BigRep Hannover Messe Recap

BigRep - Hannover Messe

Hannover Messe over but we’re still buzzing with excitement, weeks later!

Held over the course of 5 days, between 1-5 April the world’s leading trade show for industrial technologies welcomed 215,000 attendees. Central themes included 5g mobile standards, autonomous systems, and integrating artificial intelligence.

“Hannover Messe 2019 showed that is the most important international platform for all technologies related to industrial transformation.” - Dr. Jochen Köckler, CEO of Deutsche Messe AG

JR5_5815

Over 6,500 exhibitors were spread out over 227,000m2. This year, BigRep showed up like never before, with partners, Bosch Rexroth to present their idea, Factory of the Future, enabled by BigRep 3D Printers. Together, the NEXT AGV (Automated Guided Vehicle), an Autonomous transport system, was presented, as well as the unveiling the NERA bike, alongside the BigRep PRO. With the help of 5G (a central theme of Hannover Messe) data-intensive processes such as quality monitoring in the multi-variant manufacturing can be outsourced to the cloud or production-related edge systems.

BigRep - Hannover Messe

German Chancellor Angela Merkel and Swedish Prime Minister Stefan Löfven presided over the opening ceremonies, and even stopped by to see the 5G Robotic Hand presented with Bosch Rexroth and BigRep. Chancellor Angela Merkel said “I remain a big supporter of open markets and free trade.”

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The NERA bike was created in 12 weeks from sketch to a functional, driving prototype, using BigRep printers, and Bosch Rexroth technology.

“This is what we at BigRep called rapid innovation. In my opinion, what the industry is currently lacking the most, is innovation. And what we do best, is rapid innovation. So, in a very short period of time, we’re taking an idea from zero, to creating a working piece of equipment. This gives our customers a true competitive advantage in the market. With BigRep printers, we enable our customers to do the same. We’re not just selling a machine, we’re selling a reliable process.” said BigRep CEO Stephan Beyer.

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Top 5 Trends at AMUG

BigRep @ AMUG

BigRep recently debuted the PRO in North America at AMUG, one of the largest additive manufacturers user conferences.

AMUG (as it has been known since 2011) has been around since the late 80s with the mission to educate and advance the uses and applications of additive manufacturing technologies. With more than 2,000 attendees solely dedicated to additive, BigRep was able to leave their footprint as the industrial leader in large-format 3D printing.
Here’s a look at the top 5 trends we saw at AMUG.

1. The Search for an alternative

Finding the best printer for your application is a challenge many companies face. At AMUG it was clear that attendees were looking for a new large-format solution. Attendees stressed the importance of open source material, faster print speeds and more precision. As one of only a few companies specializing in large-format 3D printers at AMUG, BigRep set itself apart as the industrial leader as it debuted the PRO with the new MXT® (Metering Extrusion Technology).

2. I Feel the Need for Speed

“I feel the need for speed” is an iconic line in the movie Top Gun, and it happens to be applicable to the additive industry as well. Users want speed, and are now demanding 3D printing companies provide it. The BigRep PRO delivers printing speeds that are 5 times faster than any FFF printer on the market. It's the difference between a part being printed in 1 day instead of 7 days. This means faster turnaround times and improved ROI.

3. The Future (or Now) is bright for end use parts

For years, people have been talking about 3D printed end use parts. The majority of additive users are still using 3D printing for prototypes, however there are some early adopters out there who are already mass printing end-use parts. Industry expert, Ajmal Aqtash from Boyce Technologies delivered a very eye opening presentation at AMUG about the value and uses of additive manufacturing. Boyce Technologies is already incorporating several end use parts in the digital kiosks they manufacture, which are located around New York City. These parts are all printed on the BigRep STUDIO. They are also printing molds for vacuum forming and exploring injection modeling. Learn more by watching a webinar on how Boyce Technologies is integrating additive into their manufacturing facility.

Boyce NY additive manufacturing 3d printing BigRep Berlin

4. I want to be in control of my materials

I want to be in control of my materials
Material suppliers are everywhere, which was made abundantly evident at AMUG. One comment we heard over and over again is “I want to pick my material supplier”. BigRep offers a full line-up of materials certified for the BigRep printers, but is also open source material. BigRep also partners with BASF, a leading material supplier who are constantly innovating to provide the best material value to additive users.

5. Bigger is better.

“But I’m not sure I need a printer with that big of a build platform,” is a comment we hear. But the question is do you sometimes need it? The value of large-format 3D printing isn’t always filling up the build envelope to the max, but having the option to utilize it when you do need to. Being able to print a full scale part is key when testing fit, function and feasibility. At AMUG, attendees mentioned different ways they were currently piecing parts together after printing in order to make the part whole. These additional steps add time, cost and labor to create. Rarely do we hear customers say that they wish they hadn’t gone bigger, it’s usually regret that they didn’t go bigger.

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

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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.

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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:
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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.

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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]

A New Dimension for Additive Manufacturing: Fully Automated and 5G Connected 3D Printer BigRep PRO

Unlocking the full potential of additive manufacturing for the factory of the future / Prototype showcase marks next step in development partnership between BigRep and Bosch Rexroth / Fully 3D printed NEXT AGV for automated manufacturing to be presented.

Hannover / Berlin (Germany), March 31st, 2019 - BigRep, the global leader in large-scale 3D printing, together with its development partner Bosch Rexroth, one of the world’s leading suppliers of drive and control technologies, will present a fully automated and IoT-integrated, 5G connected 3D printer BigRep PRO at the upcoming Hannover Messe (April 1-5, Bosch Rexroth, hall 17, booth A40). As an industry-first showcase, this prototype solution marks one of the groundbreaking next steps towards the factory of the future. In addition, a 3D printed AGV (Automated Guided Vehicle) will be presented as a key tool in automated manufacturing systems.

Powered by BigRep’s proprietary, exclusive Metering Extrusion Technology MXT®, and a state-of-the-art Bosch Rexroth motion control system, the PRO delivers unprecedented speed, precision, quality and IoT connectivity that fully integrates with Industry 4.0. The BigRep PRO is the German-engineered company’s next-generation 3D printer, providing engineers with the ability to create functional prototypes, as well as composite tooling, end-use parts and small-number serial production using high-performance materials. The PRO can be ordered now.

“Our new printers are the launching pad for the factory of the future. We are opening a new dimension for additive manufacturing by establishing industrial 3D printing in automated and IoT-integrated systems. BigRep’s quality solutions meet the industry’s requirements for precise, controlled and efficient machines with full data integration,” said BigRep CEO Stephan Beyer, PhD. “We will establish 3D printing as an added value production technology in industries such as automotive, aerospace, consumer goods, manufacturing and more.”

„Over the medium term, additive manufacturing cannot ignore the need to adept to the standards of established production processes,” said Thomas Fechner, Head of the Business Unit New Business at Bosch Rexroth. “The goal is a completely digital workflow. The data must be able to pass consistently – from the customer order, the CAD software and simulation environments to specific machine movements and quality assurance.”

The BigRep PRO is meeting these requirements. Equipped with industrial IoT solutions from Bosch Rexroth and Bosch Connected Industry, the machine’s IoT devices, software and intelligent sensors such as, for example, a vibration sensor, transparently monitor all operating conditions. Another key element of the prototype showcase is an integrated 3D scanner for mid-print product quality inspection.

This solutions reduces rejects and reproducibly increases the quality of the printed components. At the same time, they increase the availability of the machine, since the software solutions detect wear and defects before they lead to machine failure. The integrated IoT Gateway software ensures that the BigRep 3D printer is connected with the industrial Internet of Things. Bosch Rexroth relies on connectivity with other machines and higher-level IT systems, because only this enables integration into connected production lines in series production.

This means that data-intensive processes such as quality monitoring in the multi-variant manufacturing can be outsourced to the cloud or production-related edge systems with the help of 5G.

Another key requirement for efficient automated production systems are inter-connected assembly and intra-logistics solutions. The challenges facing production planning in the factory of the future are escalating because manufacturing customized products and small batch sizes requires greater flexibility. Autonomous transport systems like the NEXT AGV (Automated Guided Vehicle), which can be experienced first-hand during the trade fair show, are getting more and more important for the factory of the future.

The NEXT AGV is a 3D-printed prototype jointly developed by Bosch Rexroth and NOWLAB, the innovation department of BigRep. Powered by an inductive energy unit running on a power grid, it can both serve as an automated logistics carrier (loading capacity: up to 250 kg) and as a platform for additional devices such as robots, for example, to be mounted.

The 3D-printed NEXT AGV offers many advantages: Contrary to the traditional and manual construction (i.e. sheet metal molding), the 3D-printed NEXT AGV is manufactured much more efficiently. Following a flexible design with the core elements (battery and electronics) serving as the unchanged base framework, the AGV’s shell design dimensions can be easily adapted to the required or changing needs without reducing the loading capacity – a key prerequisite for flexible industrial applications. Other key elements of the NEXT AGV are special 3D-printed wheels with two different materials, allowing the platform to move sidewise as well, and an integrated safety feature (Human Detection Antenna), which has also been 3D-printed.

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.

To arrange an interview with BigRep’s executive management team on site in Hannover, and for more information on BigRep and its solutions, please contact:

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

The BigRep PRO Makes its North American Premiere at AMUG

Powered by BigRep MXT® and state-of-the-art CNC control systems and drives by Bosch Rexroth, the PRO delivers unprecedented speed, precision and quality for industrial applications and full connectivity to integrate additive manufacturing with Industry 4.0.

Chicago, IL, March 27, 2019 - BigRep, the global leader in large-scale 3D printing, will debut its highly anticipated all new PRO at AMUG (Additive Manufacturing User Group) Conference in Chicago (March 31 – April 4, 2019). For the first time in North America, attendees from various industries can experience the PRO. Equipped with BigRep’s new MXT®, an exclusive Metering Extruder Technology, and a state-of-the-art Bosch Rexroth motion control system, the PRO delivers unprecedented speed, precision, quality and IoT connectivity that fully integrates with Industry 4.0. The PRO can be ordered now.

During AMUG, BigRep will offer two exciting presentations in partnership with industry experts. During the first session “Speed, Precision and Connectivity for Factory 4.0”, BigRep and Bosch Rexroth will team up to share their vision for the factory of the future, the vital role that additive will play and how to fully connect 3D printing into a manufacturing process. The second presentation “How Large-Scale Additive is Transforming Industries” will feature experts from Boyce Technologies and Ford Motor Company, as they share case studies for prototyping, tooling, patterns/molds and end-use parts. The experts will also discuss the added value for manufacturers and how and why leading companies are integrating AM into their production strategies.

“We are proud and excited to have our partner, Bosch Rexroth, and customers, Boyce Technologies and Ford, join us at AMUG to share their expert insights on the value and future of additive manufacturing,” said BigRep CBO, Frank Marangell. “Our latest technology offers customers complete solutions for integrated additive manufacturing systems, enabling companies to reimagine how they produce parts from design to production.”

All throughout AMUG, BigRep will be conducting live demonstrations of the PRO. During the demo, attendees will get to see up close the PRO’s one cubic meter build envelope and large, temperature-controlled spool chamber allowing for continuous printing with high-performance materials. Plus learn more about the software and state-of-the-art technology powering the PRO including the new CNC control systems and drives by Bosch Rexroth and BigRep MXT®.

“Our new groundbreaking MXT® system is something the industry has been waiting for, as it makes the PRO five times faster with greater precision and quality than current extrusion speeds,” said BigRep CEO, Stephan Beyer, PhD. “And AMUG, which encompasses a wealth of additive knowledge and industry leaders, is the perfect place to introduce the PRO to the North American market and demonstrate its full performance capabilities.”

BigRep events at AMUG at a glance:

BigRep presentations

  • Tuesday, April 2 from 1:30 – 2:30 pm (Wilford A/B), “Speed, Precision and Connectivity for Factory 4.0” by Stephan Beyer, PhD, BigRep CEO, and Karl Rapp, Bosch Rexroth.
  • Thursday, April 4 from 3 – 4 pm (Wilford C), “How Large-Scale Additive is Transforming Industries” by Frank Marangell, BigRep CBO, Ajmal Aqtash, Boyce Technologies, and Lars Bognar, Ford Motor Company.

Live BigRep PRO demonstrations in salon C, room 3

  • Monday, April 1 from 3 to 4 pm
  • Wednesday, April 3 from 1:30 to 2:30 pm
  • And upon request

About BigRep:

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

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

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

Solidworks world 2019 – where possiblilty take form

BigRep joined more than 6,000 makers, doers and innovators and 100 partners in Dallas, Texas at SOLIDWORKS World (SWW) 2019. SWW is a collective experience that inspires and activates your capacity to bring to life ideas that change the world. This year’s theme was “Where Possibility Takes Form” and BigRep showcased some interesting applications of just this.

Possibility taking form with additive

3D printing enables designers to think outside the box and explore possibilities, not just dream them. On display were several examples of prototypes designers created – marine propellers, bike helmets, a headrest from Deutsche Bahn, and the ever popular Formula ONE car display. We also highlighted the end use part that Boyce Technologies is creating for emergency system kiosks in New York. Lastly, we featured the viral sensation – the airless bike tires – but this time, installed them on a bike that you could ride. Press, attendees, and of course our team, each took rides around the booth on it. When we asked what people thought of it, they said, “It’s like riding a bike! But better because your tires will never go flat.”

bigrep-sww-2019-02

“That’s your smallest printer?”

Being one of the only large-scale 3D printing providers at SWW really set BigRep apart from the other partners. The sheer size of the BigRep STUDIO on display attracted people to the booth and when we told attendees that this was the smallest printer in our portfolio at a half meter by half meter by a full meter, we were met with both shocked and intrigued looks. Immediately, we could see them start to envision how large-scale 3D printing could help improve their designs and product development.

bigrep-sww-2019-03

Materials for your application

BigRep also showcased the full product line-up of BigRep certified materials including PLA, TPU, and the newest PA6/66 (available for the all new PRO). BigRep certified materials allow designers to prototype their designs at full scale in a cost effective way. But a great feature of all BigRep printers is that they are open-source materials, allowing customers to have a choice in what material they use.

Where to next?

Join the BigRep team at AMUG in Chicago from March 31st to April 4 and then on to Detroit for RAPID+TCT, May 21 – 23rd. Check out our full schedule of events around the world online here .


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