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.

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]

We use cookies and other tracking technologies to improve your browsing experience on our site, show personalized content and targeted ads, analyze site traffic, and understand where our audience is coming from.
By choosing I Agree you consent to our use of cookies and other tracking technologies.

Privacy Settings saved!
Privacy Settings

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. Control your personal Cookie Services here.

These cookies are necessary for the website to function and cannot be switched off in our systems.

In order to use this website we use the following technically required cookies
  • wordpress_test_cookie
  • wordpress_logged_in_
  • wordpress_sec

For perfomance reasons we use Cloudflare as a CDN network. This saves a cookie "__cfduid" to apply security settings on a per-client basis. This cookie is strictly necessary for Cloudflare's security features and cannot be turned off.
  • __cfduid

We embed videos from our official YouTube channel using YouTube’s privacy-enhanced mode. This mode may set cookies on your computer once you click on the YouTube video player, but YouTube will not store personally-identifiable cookie information for playbacks of embedded videos using the privacy-enhanced mode.
  • VISITOR_INFO1_LIVE
  • PREF
  • CONSENT
  • GPS
  • YSC

This website uses ActiveCampaign (AC) as the designated CRM to track user interaction (trough trackcmp.net) AC cookies are necessaries but no IP or personal data will be saved if you don't convert on one of our forms (cookie visitorEmailAC). We use this to better understand how people interact with our site and to see their journey through the website.  
  • ac_enable_tracking
  • visitorEmailAC

Contains the current language of the admin and the user.
  • _icl_current_admin_language
  • _icl_current_language

Cookie required to allow a user to stay logged in to a web site without needing to submit their username and password for each page visited. Without this cookie, a user is unable to proceed to areas of the web site that require authenticated access.
  • PHPSESSID

These cookies are set by WordPress are used for indication and identification of the logged in user. Those are session cookies.
  • wordpress_logged_in_
  • wordpress_sec_
  • wordpress_test_cookie
  • wp-settings-
  • wp-settings-time-

Decline all Services
Accept all Services
The BigRep NEWSLETTER
Subscribe to our newsletter for useful tips, news and resources around industrial 3D printing.
JOIN FOR FREE
X