Bigger is Better in 3D Printing

Big 3D Printing: Bigger is Better

Recently, a 3D printed house went on sale in New York, first of its kind. Pretty remarkable, but it’s still considered a novelty and must overcome several barriers before successful market adoption.

The additive manufacturing industry is advancing at an incredible pace and technology improvements, material capabilities, use cases, competitors and adoption are at an all-time high with no signs of slowing.

According to a collection of reports compiled by AMFG, the anticipated annual growth rate until 2023 is anywhere between 18.2 - 27.2%. What was once a $3 billion industry in 2013 may exceed $30 billion in just a decade. This is driven primarily by major industrial players operating in North America, Europe and Asia. As adoption increases, so does the need for scalable technology that can solve the problems of today and tomorrow. As an industry we have historically looked at speed and reliability as major requirements, but recent data suggests that size has become a very important factor to industrial manufacturers, product developers and designers.

Size Matters

There are large format 3D printers available today that are being applied to a variety of industries and applications. For example, fabrication facilities and foundries are integrating larger printing technology to create new casting patterns that are more precise and cost effective. These foundry patterns can range from 100,000mm2 up to 400,000mm2 and are typically built through a manual process that is imperfect and expensive.

Being able to digitally design and 3D print with repeatable results continues to be a distinct advantage. The concept of large in this market is determined by application, and the one size fits all approach does not apply. Below is a list of the prime examples and industrial use cases to further justify what may work for you.

Large Parts

This is highly relevant for automobile, transportation and aerospace manufacturers. Engineers in these industries design all sorts of products, prototypes and tools that can benefit from a large platform 3D printer. For example, a luxury car designer wants to create custom bucket seat options for premium customers who are eager to personalize their vehicles.

Building a human-sized prototype seat would typically require multiple 3D printed parts that must be bonded or welded, and if the tolerance is off on one print then the whole part needs to be redone. Large format 3D printing solves this unique problem by simply starting and finishing the entire part during one print. In addition, this technology has proven to be a useful manufacturing tool for production lines. Train and plane manufacturers work with very large and heavy frames, chassis and doors during the assembly process. Although most of this can be automated with industrial equipment, some of it requires manual labor due to complexity or lack of resources.

Many industrial manufacturers are building custom jigs, fixtures and manufacturing aids to enhance the worker environment and improve efficiencies. These are oftentimes paired with scanning and reverse engineering technology, which tends to be a successful and safe application of large format 3D printing.

Big 3D Print Ford Production Jig
Car Production Tool for Positioning in Assembly at Ford

Batch Part Production

3D printing is quickly gaining notoriety as a production tool that will improve manufacturing independence. The global supply chain is shrinking, and antiquated methods of overseas production are becoming a thing of the past. This is apparent for many consumer products, electronics and medical device manufacturing companies who cannot operate with long lead times.

The beauty of large format 3D printing is not just for large parts but for batch production parts. Why not fill up a build tray with 10, 50, 100 or 1,000 parts and print them overnight? Oftentimes referred to as on-demand manufacturing, this enables product development companies to immediately provide products to their customers. This reduces the need for warehousing and eliminates logistical nightmares associated with overseas transportation. As companies begin adopting the digital warehouse concept, they will continue to embrace large format 3D printing as an advantageous way to enhance customer relationships.

Big 3D Print Batch Printing
Air Duct in a Verizon Kiosk in the NCY Subway by Boyce Technologies

Immediate Iterations

How often do you design the perfect product the first time? It’s almost impossible. As engineers, our job is to iterate and improve upon designs to maximize functionality, aesthetics or any other requirement. Occasionally referred to as rapid prototyping, 3D printing has become the obvious tool selection for most product development companies who are bringing products to market. For reference, the average new product development lifecycle timeline is about five months for consumer products.

This further demonstrates that the competition is constantly innovating and it’s up to the engineering team to identify cost effective ways to get to market faster. One way is with large format 3D printing and the overnight production of multiple parts, assemblies, ideas and product iterations on a single build platform.

Conventional manufacturing methods are limited when it comes to the automation of multiple parts in a single process, and typically requires multiple days of setup time, labor, post processing, etc. Imagine printing multiple variations of your prototype, functionality testing them and having a verifiable design by the end of the week.

Big 3D Print End Use Product
3D Printed Water Scooter by Jamade

Conclusion

Size is relative. What works for you may not work for someone else, so it’s always important to conduct your own research. The 3D printing marketplace is full of complicated technologies, so understanding the positives and negatives can become quite challenging.

When it comes to determining what size platform works for you, we invite you to consult with one of our experts. With close to a decade’s worth of experience providing technology solutions and a long list of satisfied customers, we feel confident in our ability to point you in the right direction.

A truly industrial 3D printing experience

The BigRep PRO is a large-format 3D printer designed for high productivity in industrial manufacturing environments. It's an advanced additive manufacturing system capable of meeting the ever-changing demands of automotive manufacturing. Able to quickly produce high-quality prototypes or industrial tooling, the PRO is a fast and reliable solution that will help you make products that can say the same.

Learn More

A truly industrial 3D printing experience

The BigRep PRO is a large-format 3D printer designed for high productivity in industrial manufacturing environments. It's an advanced additive manufacturing system capable of meeting the ever-changing demands of automotive manufacturing. Able to quickly produce high-quality prototypes or industrial tooling, the PRO is a fast and reliable solution that will help you make products that can say the same.

Learn More

Help Stop the Spread of COVID-19 with BigRep

Get involved by additively manufacturing protective equipment for your local community with BigRep.

The ongoing effects of COVID-19 are overwhelming many hospital and organizations who lack the supplies to respond as effectively as they can, and additive manufacturing is a technology with a unique capacity to make a difference. We’re asking you to be part of the solution and print protective face shields for organizations and citizens in your local community.

BigRep is already donating face shields to local organizations to provide protection from the novel coronavirus and we’d like you to join us. With the following face shield design you can help provide some desperately needed equipment in your community. On a BigRep ONE users can print up to 24 of the masks at once, so we're asking our network of partners and customers to get involved. To help, we’re offering a complementary 2.3kg spool of PLA in exchange for video footage of you producing the equipment on your BigRep 3D printers. We’ll use that footage to continue our call for action, getting more and more people involved in this movement.

Help Stop the Spread of COVID-19 with BigRep

The process is simple:

  • Download our face shield design file (130 mb)
  • Print as many face shields as you can
  • Source clear plastic screens for the shields
  • Donate the equipment to organizations in your community
  • Send video footage of your local action to BigRep for more material

Send your video footage to Amir Fattal ([email protected]), and if you need any help connecting to local organizations who might need these supplies please reach out to Alexander Levit (alexa[email protected]).

Covid-19 Face Shield

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]

Post-Processing for FFF Prints

3D Print PPost Processing eBook

EBOOK
Post-Processing for FFF prints

BigRep provides high-quality prints straight off the print bed, but post-processing can improve geometric and mechanical properties and creates a wowing aesthetic effect. By improving surface characteristics, post-processing widely extents the range of use cases and applications across all industries.

This eBook will explore the three types of FFF post-processing techniques: 1) Material Removal, 2) Material Addition and 3) Material Property Change. Also, learn how various techniques like high resolution tumbling, resin coating and aluminum plating are transforming 3D printed parts.

COMPLETE THE FORM TO DOWNLOAD OUR POST-PROCESSING EBOOK

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[PDF 2,30 MO]

Two centuries of design meets 3D printing

EBOOK
VILLEROY & BOCH 3D PRINTING INDUSTRIAL DESIGN PROTOTYPES

Villeroy & Boch, a well known manufacturer of ceramics, is using the BigRep ONE to maximize prototyping and designing speed.
Johan de Groot, who works as a product designer, describes how the use of the BigRep ONE revolutionized the way they create prototypes and designs.
They are now able to produce bathtubs and shower trays one-to-one at high levels in about three weeks. This was unthinkable before the introduction of the BigRep ONE.

Firms across industries use BigRep’s large-format industrial 3D printer technology to reduce costs, develop better products and get to market quicker.

COMPLETE THE FORM TO DOWNLOAD OUR VILLEROY & BOCH  EBOOK

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[PDF 3,23MO]

Cheaper & faster 1:1 prototyping

Fast industrial prototyping with BigRep 3D Printers - Download Ebook today

EBOOK
CHEAPER & FASTER 1:1 PROTOTYPING

HOW THE BIGREP ONE HAS ENHANCED FURNITURE DESIGN PROCESSES AT STEELCASE

Steelcase, global leader in office furniture and space solutions maximizes their prototyping efficiency with the BigRep ONE.

Their designers in the Learning + Innovation Center (LINC) are using the the BigRep ONE 3D printer to create full-scale samples of their new projects. It allows them to have human scale version of their models and have a better idea of the way the final product would fit in a working space. With the 3D printer they try different patterns and can validate the best concepts.

“It’s quite a luxury to have such a large 3D printer to play with.” – Michael Held – Dir, Design EMEA & APAC at Steelcase.

Firms across industries use BigRep’s large-format industrial 3D printer technology to reduce costs, develop better products and get to market quicker.

COMPLETE THE FORM TO DOWNLOAD OUR STEELCASE  EBOOK
(Seeing your Email? You are already registered by BigRep! Simply click “Yes, Get the eBook”)

DOWNLOAD
[PDF 1,77 MO]

We 3D printed a sensor with conductive material

WE 3D PRINTED A SENSOR WITH CONDUCTIVE MATERIALS

EBOOK
WE 3D PRINTED A SENSOR WITH CONDUCTIVE MATERIALS

YOU CAN IMAGINE IT. YOU CAN DESIGN IT. YOU CAN PRINT IT

Industrial designers often dream up new products and then explore ways to manufacture them. Every now and again a highly innovative product emerges the other way around.
Daniel Büning and Jörg Petri, the founders of [email protected], were inspired by the potential of 3D printing. As Büning recalls, “We saw immediately that it would be a really nice idea to print modules that could be stacked together to create a space divider for an office space or a living room.” To properly test the capabilities of the technology, they added three extra requirements to their brief: incorporation of sound-proofing properties; an integrated lighting system; and a 3D-printed sensor to control the lighting system.

COMPLETE THE FORM TO DOWNLOAD OUR EBOOK

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[PDF 1,73MO]

Fast custom concrete

3D printing - Construction industry, ebook to download for free

EBOOK
GEIGER 3D PRINTING CONCRETE CASTING MOLDS

Find out how [email protected] and the construction company Geiger GmbH are using the BigRep ONE to create giant casting molds way faster than with conventional methods.

NOWLAB @BigRep presents a 3D printed formwork solution for concrete casting.
This giant mold was printed with the BigRep ONE for the Geiger GmbH, a german construction company based in Ansbach. It was used to rebuild the lintels as part of the buildings renovations. It enabled the client to save time and material.

Firms across industries use BigRep’s large-format industrial 3D printer technology to reduce costs, develop better products and get to market quicker.

COMPLETE THE FORM TO DOWNLOAD OUR GEIGER EBOOK

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[PDF 2,10MO]

Deutsche Bahn goes additive with BigRep

Download our free ebook - 3D printing

EBOOK
DEUTSCHE BAHN GOES ADDITIVE WITH BIGREP

Find out how we designed a new Material for “Deutsche Bahn” so they can print perfect spare parts on demand to save on valuable storage space.

Deutsche Bahn wanted an alternative to the holding and maintaining huge warehouses for spare parts. BigRep was asked to develop a new material that complies with company and EU standards in order to enable spare part on-demand manufacturing.

Firms across industries use BigRep’s large-format industrial 3D printer technology to reducecosts, develop better products and get to market quicker.

COMPLETE THE FORM TO DOWNLOAD OUR DEUTSCHE BAHN  EBOOK

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[PDF 2,30 MO]

Villa Ancora – 3D Printed Architectural Model

villa-ebook

EBOOK
Large Architectural Model 3D Printed in Only 11 Days

See how a BigRep industrial 3D printer effortlessly produces a complex architectural model in full detail and with a beautiful, high-impact finish.

BigRep printed an elaborate, contemporary villa concept in 1:50 scale in just 5 days, plus 1 day for slicing and 5 more for post-processing. The 3D model contains all the important complex elements in the intricate CAD design it is based on.

COMPLETE THE FORM TO DOWNLOAD OUR VILLA EBOOK

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[PDF 3,60 MO]

 

High-Performance 3D-Printed Bionic Propeller

bionic-ebook

EBOOK
3D Printed Bionic Propeller
Industrial Design Metal Cast Pattern

The Bionic Propeller is an innovative component designed to increase thrust performance by 19% and reduce noise emissions by 30%.

The BigRep ONE comes into its own to precision-manufactures large, complex, research-driven industrial designs like this. The Bionic Propeller design incorporates two principles inspired by nature. Both of these bionic principles work in water and air so the design could be adapted for various applications.

3D prints of parts like this can be used as patterns for metal casting, reducing costs and lead times and allowing for greater complexity to be integrated into industrial production.

COMPLETE THE FORM TO DOWNLOAD OUR BIONIC PROPELLER EBOOK

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[PDF 2,15MO]

BigRep PRO large scale 3D Printer
DISCOVER OUR NEW EBOOK
HOW TO REDUCE LEAD TIME WITH IN-HOUSE SUPPLY CHAINS
DOWNLOAD NOW
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