User Stories – BigRep Industrial 3D Printers

Large Scale 3D Printing Shines New Light on Laser Research

Natasha Mathew — Tue, 14 Jan 2025 10:57:49 +0000

LZH uses large scale 3d printing for laser research by creating custom experiment environments with the BigRep VIIO 250.

Laser Zentrum Hannover e.V. (LZH), a leading research center in Lower Saxony, Germany is dedicated to laser technology, encompassing the study of optics, lasers, quantum technologies, smart additive manufacturing, and other relevant fields.

The Optical Components Department in the institute focuses on photonic materials, smart optical devices, optical coatings, and optics integration. Joshua McCauley is a Research Associate in the department and a major portion of his work involves understanding the optical properties of different materials. Simply put, in his experiments, he beams laser onto optical samples and measures how much heat they absorb and how quickly they cool down.

Typically, aluminum chambers are used for these experiments but they proved limiting to Joshua as he faced challenges in creating a temperature-stable environment. The holes for the laser to enter and exit the chamber caused issues like unwanted airflow and temperature changes, making the experiment's results unreliable.

The Challenge: Customizing Experiment Environments

Joshua McCauley with the chamber 3D printed by the BigRep VIIO 250.

The traditional aluminum experiment chamber had troubles with:

Limited design flexibility constrained by fabrication methods such as injection moulding.
Poor thermal isolation allowed external temperatures to interfere with experiments.
High costs associated with outsourcing the construction of custom metal parts needed for the experiment.
Optical experiments often require modular setups to house different configurations of laser beams. The aluminum chamber did not have custom parts for the entry and exit of the laser beams which led to convection issues and temperature fluctuations.

Large Scale 3D Printing for Laser Research

LZH’s facilities at the Centre for Additive Manufacturing

LZH has been well-equipped with the latest additive manufacturing machines, which include a BigRep machine - the STUDIO that had a solution for Joshua McCauley. Matthias Henzler, from the additive manufacturing department at LZH, stepped up to the task of fabricating the chamber using 3D printing.

“ We were looking for a large-scale 3D printer with two main requirements. It needed to have a closed build chamber and the ability to print with two materials at the same time and the BigRep VIIO fit the bill ”

- Matthias Henzler, employee at Laser Zentrum Hannover e.V.

The Chamber Design

The two walls are designed to further insulate the chamber for accurate experiment results.

The chamber was designed with a reduced surface area to minimize the thermal effect of the lab environment and has two parts - a roof and a bottom half. In the middle, there is a piece where the laser beam passes through, which can be swapped out depending on the type of lens or angle required for the laser. This modular set-up is for easy adjustment which helps control unwanted airflow or temperature fluctuations.

The part through which the laser passes through in the 3D printed chamber.

The two walls in the chamber reduce the heat transfer and are only slightly connected at the bottom. The space between them can either be left empty or filled with insulating materials like foam or sand to further control thermal effects.

Reasons for Going Big with 3D Printing

Matthias Henzler 3D printing with the BigRep VIIO at LZH.

Design Flexibility
The ability to print complex, non-standard shapes allowed the team to create custom chambers that would be difficult or impossible to construct with aluminum. For example, modular chambers with swappable components could now be designed, offering the flexibility to modify the setup depending on the experiment.
Thermal Isolation
The dual-wall chamber design helps maintain a stable temperature. This configuration offers thermal isolation, as the walls were separated, and the space between them could be filled with insulating materials like foam or sand. The result was a reduced impact from external temperature fluctuations.
Scalability
With BigRep VIIO’s large build volume of 1000 mm x 500 mm x 500mm, the research team could print the entire chamber structure, not just small components. This scalability was essential for creating the large-scale parts needed for optical experiments, something desktop 3D printers couldn’t handle.
Cost Efficiency
Instead of outsourcing, which is both expensive and time-consuming, Joshua was able to have the chamber fabricated on-site with the BigRep VIIO. This eliminated the prohibitive costs and helped him experiment with design and prototype at lower costs.

Using the VIIO is stress-free because it reliably completes parts with minimal effort. Automation features like the one-click start, preheating, and bed mapping allow you to focus on other tasks while the printer produces precise parts.”

- Matthias Henzler.

WHY THE BIGREP VIIO 250

Advanced Automation

Automated features such as bed mapping, one-click start, filament flow rate adjustment, and x/y calibration save valuable time, and researchers can focus on other tasks.

Enclosed Build Chamber

The actively temperature-controlled build chamber heats up to 50°C and delivers consistent results regardless of the complexity or size of the parts.

Dual Extruders Print with Different Materials

One of the key features of VIIO that LZH was sold on was the 3D printer's ability to print with two materials in a single print job.

Large-Scale Build Volume

The generous build volume of 1000 mm x 500 mm x 500 mm (250 liters) is perfect for large parts that LZH’s smaller 3D printers cannot handle.

Precise Parts

The VIIO 250's print bed ensures uniform heat distribution for consistently robust parts and strong part adhesion which can be cleanly popped off as the printer cools down.

Ease of Use

The machine user interface has animated guides that deliver clear information, alerts, and warnings to help researchers easily manage their print jobs.

Seeing Optical Research in a New Light

Large-scale 3D printing offers the flexibility to explore big ideas that were previously cost-prohibitive for Joshua McCauley. Instead of outsourcing the production of the chamber, he was able to get it 3D printed in-house with the material of his choice which made experimentation affordable and well within his reach.

At LZH, the BigRep VIIO has created more opportunities for collaboration with industry partners interested in large-format 3D printing. The 3D printer is not just a tool for current projects but a key to future breakthroughs in optical research and industrial applications.

About the author:

" />

Natasha Mathew

Copywriter

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

How 3D Printing is Paving the Way for Grading Contractor, C.J. Moyna & Sons

Natasha Mathew — Tue, 05 Nov 2024 08:33:51 +0000

The heavy civil construction sector (e.g. highway road construction, mass excavation) is literally heavy-handed when it comes to engineering and manufacturing new components. The bottleneck is that it takes an eternity with conventional methods to materialize these parts.

For Ryan Young, a project manager at C.J. Moyna & Sons, being on the lookout for disruptive technologies is a part of his everyday routine. When they set on a path to integrate additive manufacturing into their daily processes, the work became easier for C.J. Moyna & Sons and their sister companies.

Founded in the 1940s, C.J. Moyna & Sons is a family-run business that has shaped the landscape of Iowa for three generations ever since. The company specializes in civil earth moving, equipment manufacturing, and aggregate processing & mining and belongs to the premier grading contractors in the Midwest.

However, the pandemic presented the company with major challenges. With the global supply chain being disrupted, the company needed to find a way to meet its demand for components.

Especially, for the Earthmoving Legacy Center, where the owner John Moyna exhibits historical construction vehicles, it was impossible to find spare parts for antique caterpillars, tractors, and scrapers.

The Earthmoving Legacy Center is a 38000 square foot facility to showcase the rich history of earthmoving.

Young and his team found a compelling solution with additive manufacturing that became a game changer. When C.J. Moyna & Sons first tried out some hobby 3D printers, it became evident that an industrial large format printer with an open material system would be a better fit.

Ryan Young, a project manager with an exhibit at the C.J. Moyna & Sons legacy center.

For Ryan Young, the BigRep PRO checked all the boxes – the massive build volume, accuracy, reliability, and the entire 3D printer ecosystem the company offered sealed the deal.

UPGRADING OPERATIONS WITH THE BIGREP PRO

Massive Size

One cubic meter fully enclosed build chamber to produce full-scale, large parts e.g. prototypes, intricate patterns in large scale, and end-use parts.

Speed & Accuracy

CNC components made by Bosch which allow rapid and precise printing results.

Open Material Platform

Compatible with both BigRep filaments and third-party materials.

Automation Features

MXT Control System using algorithms and surface mapping for automated print bed and extruder calibration.

Patrick Palmersheim, System Administrator, uses the BigRep PRO to restore parts of the construction vehicles in the legacy center which are pretty much impossible to find anymore. Thus, the company’s heritage is being cared for and kept alive. Palmersheim also praised BigRep’s engineers who helped him solve smaller issues.

C.J. Moyna & Sons doesn’t strictly use the BigRep PRO for restoration. Ryan Young says that they use it for rapid prototyping which supports sister company Mobile Track Solutions, for manufacturing mock-ups, functional dash parts, and final parts.

For the R&D team, the PRO prints functional dash parts in a couple of days. E.g. with the injection molding process, it would have taken weeks or months.

“In 2 or 3 days you can have a large functional piece printed by the BigRep PRO – ready to rock and roll.”

Speaking about the filament, Ryan Young likes the fact that the BigRep PRO prints with materials from different brands which makes the industrial 3D printer versatile. His favorite filament is the PRO-HT – a biopolymer with reduced environmental impact which is easy to print, FDA compliant for food safety, and formulated for effortless breakaway support removal.

After the printing process, the rapid innovation manager says some post-processing is needed, but “a lot of time the parts are in a good shape when they come out the printer.”

Driving the Future

For Paul Palmersheim, it’s been a really great experience working with BigRep. And for Young? He says it’s had “a tremendous impact” on how they are manufacturing and looking towards the future of engineering. From his point of view, 3D printing will be growing and improving in the future. And his prediction: “I can see in another 10-15 years, 25-30% of parts are gonna be 3D printed.”

Want to learn how Industries are expediting Product Development with 3D Printing?

Reduce Cost and Lead Time with Industrial 3D Printing in Product Development.

Design Prototypes for Industrial Production

Prototyping design iterations is faster and easier as part of a seamless digital workflow
Get better-informed feedback regarding part fit, function, aesthetics, and more with full-scale prototypes
Accelerate time to market with 3D printed prototypes produced in a fraction of the time

Learn more

Production 3D Printer

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

Key Features

Enclosed 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 grams per hour.
Removable Flexible Print Bed (Up to 100 °C): A heated bed with a flexible, magnetic, interchangeable surface that enhances print adhesion and minimizes warping.
Numerous Automation Features: Print bed and extruder calibration for quick, easy set up and optimal print quality.

Key Features

Enclosed 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 grams per hour.
Removable Flexible Print Bed (Up to 100 °C): A heated bed with a flexible, magnetic, interchangeable surface that enhances print adhesion and minimizes warping.
Numerous Automation Features: Print bed and extruder calibration for quick, easy set up and optimal print quality.

Explore the PRO

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

Enclosed 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 grams per hour.
Removable Flexible Print Bed (Up to 100 °C): A heated bed with a flexible, magnetic, interchangeable surface that enhances print adhesion and minimizes warping.
Numerous Automation Features: Print bed and extruder calibration for quick, easy set up and optimal print quality.

Explore the PRO

About the author:

" />

Yücel Uzunoglu

Guest Author

If you ask Yücel, every good story needs one main ingredient: the curiosity of a 6-year-old. The copywriter hasn't lost it, even after more than a decade in the communications industry. His story now continues at BigRep, where the “jack-of-all-trades” shares his curiosity for 3D printing with like-minded people.

3D Printed Dragon Brings in the Chinese New Year

Jason Tzintzun — Wed, 16 Oct 2024 16:52:41 +0000

In the heart of the art district in Tampa, Florida, Artistic Spaces is a design studio known for its avant-garde sculptures and large-scale installations. While the studio specializes in creative custom fabrications, some of its major projects faced significant challenges with scalability, materials and labor costs, complex geometries, and time constraints.

The owner of the studio, James Murray, recognized that to maintain their competitive edge and meet growing demands, he needed to upgrade their fabrication to more technologically advanced methods. His journey towards overcoming these obstacles began in December 2023 when he purchased the BigRep ONE 3D printer from a local reseller, ELK3D, a veteran-run partner specializing in advanced 3D printing solutions.

The Challenges Artistic Spaces Faced

James and his team had challenges with:

Scalability: Traditional methods couldn't easily scale to larger projects.
Cost: The expenses involved in traditional sculpting materials and labor were skyrocketing.
Time: The time required to produce large art pieces hindered their ability to take on more projects and meet client deadlines.
Geometric Complexity: Traditional manufacturing methods were too labor-intensive and produced lower-quality results for intricate geometries.

BigRep's Solution

Artistic Spaces was introduced to BigRep’s catalog of large-scale industrial 3D printers, specifically the BigRep ONE, by ELK3D. James Murray from Artistic Spaces said,

“This was our first experience working with a large-scale 3D printer, and the entire process exceeded our expectations. Once we had the model in the slicer, it was easy to write the code and watch it print.”

Artistic Spaces ordered the BigRep ONE with ELK3D in mid-December, and it was delivered on the 28th, a couple of weeks later. BigRep printers are manufactured in Germany and have a facility in Boston, Massachusetts. Thanks to meticulous planning, efficient logistics, and the ability to maintain stocked inventory in the USA, ensuring (JIT) just-in-time delivery, ELK3D, and BigRep delivered the machine to Artistic Spaces in Tampa within a few weeks.

The BigRep ONE offered:

Massive Build Volume: Can produce pieces up to one cubic meter or 31 cubic feet, perfect for large installations.
Cost Efficiency: The open material system, flexible scale and design capabilities, and automated production reduced costs significantly.
Speed: Drastically cut down delivery time through automated production and fewer failed prints allowing Artistic Spaces to take on more projects and deliver them quicker.
Geometric Precision: Enabled the creation of complex geometries with high precision and quality.
Reliability: Ensured consistent performance and high-quality output, minimizing downtime and enhancing productivity

ELK3D's technical leader, Taylor Hardy, was on-site to oversee the delivery and installation of the printer. The team efficiently unboxed, assembled, and calibrated the BigRep ONE in less than two days. As part of the ELK3D’s Assurance program, Taylor ensured the Artistic Spaces team received thorough training, and was well equipped to operate the printer confidently.

James Murray from Artistic Spaces said,

“The BigRep ONE ran nonstop for three days without any issues. Thanks to ELK3D's onsite training, our team confidently use the machine, we simply hit the start button and get on with our tasks while the machine takes care of the part.”

This Assurance Program and rapid setup included:

Detailed Guidance: Taylor provided step-by-step instructions for every function of the BigRep ONE, covering everything from basic operations to advanced settings. This included practical demos of how to use the machine efficiently, along with best practices to ensure longevity and consistent performance.
Test Prints: Taylor facilitated initial test prints to verify the machine's calibration and optimize printing These test prints were essential in fine-tuning the printer's settings, ensuring that the output was of the highest quality and that the machine was running at peak efficiency.
Comprehensive Training: Taylor and the ELK3D technical team conducted in-depth training sessions with James, the lead artist at Artistic Spaces which included flow rate calibrations tailored to different materials, enabling him to adjust the printer settings for different filaments. Taylor also covered troubleshooting techniques and routine maintenance procedures to ensure long-term performance and minimize downtime.

Over the next few days, the team printed several sample pieces to understand the machine's capabilities. One of the first large-scale projects was a dragon sculpture for the Chinese New Year celebration at the Hard Rock Hotel in Tampa.

Chinese New Year and the Dragon Project

Chinese New Year, or the Spring Festival, is China’s most important traditional celebration, marking the start of the lunar new year. For the occasion, Artistic Spaces was commissioned to create a dragon sculpture for the Hard Rock Hotel in Tampa. Despite initial challenges with print settings, the team, with support from BigRep's engineers, successfully printed the dragon's head in 3 ½ days.

The large-scale 3D printed dragon head was executed by the BigRep ONE.

The combination of 3D printed precision and hand-carved craftsmanship resulted in stunning dragon sculptures in a large and smaller scale that seamlessly blended tradition with technology.

The smaller scale dragon 3D printed by the BigRep ONE.

Technical Training for the Dragon Sculpture’s Execution

ELK3D Assurance Program included:

Project Consultation: In-depth discussions on project requirements and strategic advice on dividing the dragon project into manageable parts.
Technique Exploration: Methods for merging printed parts seamlessly post-production and applying specialized coatings to enhance durability and aesthetics.
Printing Setup and Support: Collaboration on slicing the dragon model file, ensuring precise settings for dual-material printing, and providing real-time assistance through screen-sharing sessions.
Material Selection and Configuration: Recommendations for PLX as the model material and PRO HT for breakaway supports, optimizing print quality, ease of post-processing, and structural integrity.

Taylor Hardy from ELK3D said,

“We partnered with BigRep because of their reliability, quality, advanced technology, and the dedicated team behind it. This collaborative environment enabled us to achieve success with Artistic Spaces, James, and his team.”

The Transformation

Within 20 days of installation, Artistic Spaces had monetized their investment by successfully completing the dragon sculpture project. They were now able to:

Expand Creativity: The freedom to experiment with new designs and scales without worrying about the constraints of traditional methods.
Increase Productivity: With reduced production times, they could take on more projects and increase their revenue.
Enhance Quality: The precision of the BigRep ONE ensured that every piece of art printed met the highest standards of quality.

The Results

Revenue Growth: In 2024, Artistic Spaces experienced an increase in revenue within the first year of using the BigRep ONE with customers asking for new concepts. New projects were rolling in, allowing them to capitalize on their new capabilities.
Project Capacity: They are able to take on more projects, thanks to the reduced production time.
Cost Savings: Material and labor costs were cut by 30%, significantly improving their profit margins.

Limitless Creativity

Given the tight timeframes and budgets, the BigRep ONE was able to accommodate large-scale projects quickly and deliver results faster than traditional methods. The digitized fabrication process opened doors to a much wider spectrum of possibilities, unlocking new dimensions of creativity and business success.

Professional 3D Printer

Large-Scale Innovation. Limitless Creativity.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. It's the trusted tool of designers, innovators, and manufacturers alike.

Key Features

Open 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
Dual Extrusion (Up to 250°C, 72 g/h): Multi-material printing capability with a dual-extrusion system, supporting a wide range of materials and a print rate of up to 72 grams per hour.
Heated Print Bed (Up to 80 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
Fine Detail or Fastest Printing: Layer heights from 0.3 to 1.0 mm let you achieve fine detail on large prints or extra fast prints when surface texture is less important.

Key Features

Open 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
Dual Extrusion (Up to 250°C, 72 g/h): Multi-material printing capability with a dual-extrusion system, supporting a wide range of materials and a print rate of up to 72 grams per hour.
Heated Print Bed (Up to 80 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
Fine Detail or Fastest Printing: Layer heights from 0.3 to 1.0 mm let you achieve fine detail on large prints or extra fast prints when surface texture is less important.

Explore the ONE

Large-Scale Innovation. Limitless Creativity.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. It's the trusted tool of designers, innovators, and manufacturers alike.

Open 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
Dual Extrusion (Up to 250°C, 72 g/h): Multi-material printing capability with a dual-extrusion system, supporting a wide range of materials and a print rate of up to 72 grams per hour.
Heated Print Bed (Up to 80 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
Fine Detail or Fastest Printing: Layer heights from 0.3 to 1.0 mm let you achieve fine detail on large prints or extra fast prints when surface texture is less important.

Explore the ONE

About the author:

" />

Michelle Green

Guest Author

Michelle Green is an accomplished Director of Business Development at ELK 3D with extensive experience driving growth through strategic partnerships, innovative solutions, and collaborative ecosystems in the technology space. With a background in 3D printing and additive manufacturing, she has earned recognition as an industry expert and speaker. Her vision is to build ecosystems where technology, talent, and partnerships thrive. She is passionate about aligning cutting-edge technology with business success and shaping the future of manufacturing through meaningful collaborations.

About the author:

" />

Jason Tzintzun

Marketing Manager

Jason is a seasoned marketing professional with over five years of experience in additive manufacturing. With a degree in English (Creative Writing) from San Francisco State University, he never anticipated his career would lead him to 3D printing, but he has discovered a true passion for educating others on its profound impact. Currently serving as the Head of Marketing for North America at BigRep, Jason brings a deep understanding of 3D printing technology and its role in modern manufacturing. When not crafting marketing campaigns, he enjoys long-distance running along the Southern California coast he calls home, and, of course, 3D printing.

The BigRep IPSO 105 Futureproofs Outdoor Fiber Cabinets

Natasha Mathew — Thu, 25 Jul 2024 13:15:27 +0000

Sichert, a 100-year-old Berlin-based company, integrates smart multi-tasking features into their fiber connection cabinets with the high-temp, large-volume 3D printer, the IPSO 105.

FTTH (Fiber To The Home), the future of high-speed internet in every household and company, is basically the connection where the fiber cable goes all the way to the user instead of ending at an anonymous cabinet down the street. 

These outdoor cabinets (FCC), although unassuming, are a critical component in present-day telecommunication. They are designed to take on the rigors of the harshest weather conditions while ensuring seamless IT infrastructure by housing servers, networking equipment, and other essential hardware. They are equal parts of form, fit, and function while blending in with the spaces in which they are installed. 

Sichert, a 100-year-old Berlin-based company, is an industry leader in producing outdoor cabinets, access chambers for fiber optic, and copper cable distribution. With innovation at the core of their offerings, 3D printing has been an integral part of their workflow for decades. While the company relied on desktop 3D printers and outsourced print projects, as their needs got bigger, they sought to invest in an in-house solution to innovate with sizable high-performance parts.

Sichert added a new player to its FFF 3D printing capabilities - the BigRep IPSO 105 - a high-temperature 3D printer, for rapid prototyping and future-proofing their products. With the 3D printer, they design cabinets that visually match their surroundings, upgrade the aesthetics, and integrate thoughtful multi-tasking features that offer smart city solutions. 

What are Fiber Connection Cabinets (FCC)?

Fiber Connection Cabinets (FCC) are specialized industrial cabinets used in telecommunications to manage and distribute fiber optic cables that extend directly to households, providing high-speed internet and data services. Their core function is to also protect cables from environmental and physical damage, facilitate splicing and termination, and ensure easy access for maintenance.

Traditionally made using expensive injection molding, parts of FCCs are now increasingly produced with 3D printing technology, allowing for rapid prototyping, cost efficiency, and greater design flexibility. This supports the growing demand for reliable and scalable fiber optic connections, essential for connecting households and businesses to the gigabit age. 

Challenges with Traditional Manufacturing

1. High Cost of Prototyping
Injection molding needs expensive molds which results in high-cost prototyping

2. Design Limitations
Metal and mold designs restrict the freedom to experiment with cutting-edge designs and structures.

3. Material Constraints
Limited range of materials that can be used, especially when it comes to high-temperature and environmentally resistant applications.

Thorsten Drochner, Director of R&D said,

“One of the biggest challenges in developing new street cabinets is that prototypes are really expensive because of injection molding. This is where the IPSO 105 brings in the advantages - prototyping, rapid prototyping, or even small iterations. It's very fast, simple and cost-effective.”

Benefits of a Large-Scale High-Temp 3D Printer

Sichert initially used desktop 3D printers to explore the potential of additive manufacturing by printing parts of outdoor cabinets. Encouraged by flexibility and cost savings, they upgraded to the IPSO 105, BigRep’s large-format high-performance 3D printer.

SCALING UP WITH THE HIGH-PERFORMANCE BIGREP IPSO 105

Large-Scale Innovation

The generous build volume of 400 mm x 600 mm x 440 ensures Sichert’s design freedom to experiment with complex structures in full-scale.

High-Temperature Applications

With the build chamber heating to 100°C, the print bed reaching 180°C, & the extruder capability of 450°C,Sichert can print high-performance parts.

Open Material Platform

Capable of printing with virtually any compatible material, especially environmentally resistant filaments, is a game-changer for Sichert's R&D team.

High Cost and Time Savings

The 3D printer, IPSO 105, reduced prototyping costs and accelerated the product development cycle with quick turnaround print time. 

Sichert’s Applications with the IPSO 105

1. Product Development

a. Smart Bench
Sichert designed an aesthetically pleasing outdoor fiber-cabinet bench with future cities in mind. It is fitted with a solar panel at the back, a phone charger to the side, and a fiber distribution cabinet within the bench. The 3D-printed parts were post-processed to give it a natural wood finish so it blends into environments where grey cabinets might stand out.

Sichert's Smart Bench outdoor fiber cabinet printed by the high-temperature industrial 3D printer - BigRep IPSO 105

b. Smart Tower
Sichert’s Smart Tower was built to house 5G small cell (a small wireless device that boosts mobile network coverage and speed in busy areas), with the side panels 3D printed for flexibility in shape and design. Built to be installed in public places, it can also double as an information point in spaces such as bus or tram stops.

The Smart Tower's side panels were 3D printed by the IPSO 105.

2. Rapid Prototyping and Design Testing

Rapid prototyping is one of the areas in which Sichert uses the 3D printer extensively, especially for all their new products, FCC cabinet series, and predominantly for their out-of-the-box designs. Prototypes of PCBs (printed circuit board) and cabinet parts are often printed and tested for tolerance, design fit checks, and stability. The printer’s capability to handle large parts without the need to cut and reassemble them ensures structural integrity and saves time.

3. Material Testing and Validation

The IPSO 105’s open material system which allows for printing with any compatible 3D print filament enabled Sichert to test a range of 3D print materials like BigRep’s environmentally resistant ASA, high-strength Polyamide with carbon fibers, and the durable Polycarbonate filament. This ensured the final part met all environmental and operational requirements.

“The IPSO 105 gives us the freedom to choose any material range from low to advanced materials like PEEK which we use in high-temperature use cases. We used to face challenges in picking the right materials which meet specific needs and with this 3D printer, we can explore our options.”

4. Trade Fair Samples

Sichert often takes part in trade shows and showcasing high-quality, visually appealing prototypes are an integral part of keeping the industry updated with their latest offerings. These 3D-printed parts are post-processed with varnish or undergo structural reinforcing treatments to give potential customers a realistic idea of what the final product would look and feel like.

Future-Proofing Outdoor Cabinets

The freedom to print in true scale, unlimited choice of material, high to low-temperature capabilities, and cost and time efficiency delivered by the 3D printer have enabled Sichert to expand the functionality and experiment with the design of their fiber cabinets.

With the IPSO 105, Sichert not only weatherproofs but also future proofs their outdoor cabinets by making them smarter and ahead of their time.

Want to learn how Industries are expediting Product Development with 3D Printing?

Reduce Cost and Lead Time with Industrial 3D Printing in Product Development.

Design Prototypes for Industrial Production

Prototyping design iterations is faster and easier as part of a seamless digital workflow
Get better-informed feedback regarding part fit, function, aesthetics, and more with full-scale prototypes
Accelerate time to market with 3D printed prototypes produced in a fraction of the time

Learn more

Production 3D Printer

Maximum Performance. Unbeatable Price.

The IPSO 105 boasts an unbeatable price-to-performance ratio. It's an industry all-rounder and high-temperature machine to reliably produce high-performance parts.

Key Features

Enclosed 105 Liters Build Chamber (Heated Up to 100 °C): Enclosed build chamber is heated up to 100 °C with highly uniform heat distribution delivering large, accurate 3D prints.
Dual Extrusion (Up to 450°C, 150 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-performance materials and a print rate of up to 150 grams per hour.
Multi-Surface Print Bed (Heated up to 180 °C): An evenly-heated bed with two surfaces: a specialized tempered glass or flexible steel plate with a magnetic foil and PEI coating for easy print removal.
Numerous Automation Features: Automated print bed and extruder calibration for quick, easy set up and optimal print quality, plus Relay Mode for continuous printing on 2 extruders.

Key Features

Enclosed 105 Liters Build Chamber (Heated Up to 100 °C): Enclosed build chamber is heated up to 100 °C with highly uniform heat distribution delivering large, accurate 3D prints.
Dual Extrusion (Up to 450°C, 150 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-performance materials and a print rate of up to 150 grams per hour.
Multi-Surface Print Bed (Heated up to 180 °C): An evenly-heated bed with two surfaces: a specialized tempered glass or flexible steel plate with a magnetic foil and PEI coating for easy print removal.
Numerous Automation Features: Automated print bed and extruder calibration for quick, easy set up and optimal print quality, plus Relay Mode for continuous printing on 2 extruders.

Explore the IPSO 105

Maximum Performance. Unbeatable Price.

The IPSO 105 boasts an unbeatable price-to-performance ratio. It's an industry all-rounder and high-temperature machine to reliably produce high-performance parts.

Enclosed 105 Liters Build Chamber (Heated Up to 100 °C): Enclosed build chamber is heated up to 100 °C with highly uniform heat distribution delivering large, accurate 3D prints.
Dual Extrusion (Up to 450°C, 150 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-performance materials and a print rate of up to 150 grams per hour.
Multi-Surface Print Bed (Heated up to 180 °C): An evenly-heated bed with two surfaces: a specialized tempered glass or flexible steel plate with a magnetic foil and PEI coating for easy print removal.
Numerous Automation Features: Automated print bed and extruder calibration for quick, easy set up and optimal print quality, plus Relay Mode for continuous printing on 2 extruders.

Explore the IPSO 105

About the author:

" />

Natasha Mathew

Copywriter

3D Printed Chandelier, The Hedron, Outshines Conventional Ceiling Lights

Natasha Mathew — Thu, 20 Jun 2024 16:37:10 +0000

Ben Mickus, an award-winning designer and practicing architect, designed and 3D printed “Hedron,” a pendant that’s light years ahead of modern chandeliers.

Design inspired by geometry in nature. Dreamy ethereal glow. Timeless gradient aesthetic. These are some images that Ben Mickus’ 3D printed Hedron pendant light conjures to the mind. The chandelier balances intricacy with playfulness, inviting you to step into an elegant space that celebrates futuristic design powered by a conscious fabrication choice.

Ben Mickus founded Mickus Projects, a 15-year-old multi-disciplinary design studio specializing in furniture, lighting, architecture, and design strategy. He honed his design skills working on large-scale cultural projects at the prestigious architecture firm, Diller Scofidio + Renfro in New York.

Over the years, Mickus Projects has engaged in a variety of research-driven prototype projects, spanning furniture, architecture, and lighting. The design studio's latest endeavor in the interior lighting space with the Hedron delved into 3D printing with bioplastics.

Photographed by Ryan Gobuty.

The Genesis of Hedron

Inspired by the geometric design of polyhedrons, Ben created the Hedron with a twist that fools the eye. One can look into and through it without actually seeing the light source inside. This geometrical trick makes the Hedron look like it’s glowing from within. Produced with translucent BigRep PLX, the printed walls are thinner at the edges and are angled precisely so the light bounces twice, creating a light-to-dark ambient glow. Almost magically, the light displays no glare and is shadow-free.

"The idea for this fixture started with the shape of a polyhedron, a multi-faceted, three-dimensional object, which has a really interesting form that naturally takes on a curve. Like a turtle shell, or an insect eye, or a soccer ball, all these things are based on polyhedrons where the curve changes between hexagons and pentagons," Ben explained.

Photographed by Ryan Gobuty.

Through parametric modeling, he was able to meticulously iterate and adjust the angles of each surface to achieve the perfect result.

“I modeled the Hedron parametrically so that the angle of all surfaces could be very carefully and precisely controlled so that you can't see the light bulb, no matter which way you look at the fixture.”

3D Printing Illuminates the Path

Ben's prototype was successfully brought to life using BigRep's large-scale 3D printer – the STUDIO. The choice of PLX, a bioplastic known for its bioplastic nature and surface quality, was a deliberate one.

“The superior surface quality achieved by BigRep's PLX was the best part. And it's the only filament that doesn't use petroleum products, which was a really big plus for me.”

Photographed by Ryan Gobuty.

The printing process presented its own set of challenges, particularly in achieving a single-part print with striated texture and complex form. The large build volume of the BigRep STUDIO was crucial to produce the 18"W X 12"H intricate design in full-scale, while also allowing experimentation with different materials before the final choice of PLX. Inspired by various post-processing methods, Ben experimented by coating the fixture in a ceramic-based sealant to achieve a matte appearance.

Design Elevated by Functionality

Hedron's design is not only aesthetically pleasing but is also highly utilitarian. It is designed to hang from a concealed inner bracket inside the stem. The fixture can be easily attached and detached without the need for fasteners, glue, or additional hardware. Ben explained, "The entire shade is just lifted up, rotated 60 degrees, and then it slips out from kind of a three-point slot in the top of the fixture." This custom component is an excellent example of how Design for Additive Manufacturing (DfAM) can consolidate components for better products requiring less assembly.

Photographed by Ryan Gobuty.

A Bright Future Ahead

The Hedron will be showcased at the Light Design Expo in San Francisco on June 20^th, which is sponsored by the Illuminating Engineering Society (IES). The event will be a platform for Ben to get a pulse of the industry, which he hopes will help in moving the Hedron towards mass production.

He is optimistic about the fixture's potential and looks forward to its reception. Keep an eye out for his futuristic Hedron at the Light Design Expo and beyond.

Photographed by Ryan Gobuty.

Want to Learn More about 3D Printing Bespoke Furniture?

Download the eBook, RH-Engineering & manoFigura 3D Print Luxury Furniture.

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

Read this additive manufacturing case study to learn:

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

HOW RH-ENGINEERING & MANOFIGURA 3D PRINT LUXURY FURNITURE

About the author:

" />

Natasha Mathew

Copywriter

3D Printing in Education: The BigRep STUDIO Takes Learning Out of the Box

Natasha Mathew — Thu, 02 May 2024 15:59:43 +0000

Integrate 3D printing in education with the BigRep STUDIO, a large-scale machine that sets students and researchers up for success with its state-of-the-art technology trusted by industry leaders.

3D printing is rooted in hands-on learning, a pedagogical tool for ambitious students and researchers to take them from concepts to physical models, preparing them for real-world success. The technology is widely used to ensure promising research outcomes through high-accuracy parts in a wide range of materials for studies ranging from engineering to art and design. While most entry-level 3D printers in the market comfortably fit on a desk, the unrestricted freedom to explore new ideas manyfold as the build volume gets BIGger.

Built with a generous build volume of 1000 x 500 x 500 mm, the BigRep STUDIO is 10 times that of a standard desktop 3D printer. It is a massive, reliable, and education-ready 3D printer built to graduate students from desktop learning to a professional industrial-grade machine. Many leading universities around the world house the STUDIO and discover applications across almost all academic and research disciplines.

Join the Ranks of Top Universities by Integrating Large-Scale 3D Printing into Your Curriculum

WHY THE STUDIO IS THE BEST-IN-CLASS
EDUCATIONAL TOOL

A Generous Build Volume

A 1000 x 500 x 500 mm build chamber for students and researchers to explore and test their ideas in full-scale.

A Safe, Fully Enclosed Build Chamber

The temperature-controlled build envelope for consistent prints and safe access to the print bed.

Open Material Platform

Freedom to print with compatible 3rd party materials including carbon-fiber-reinforced plastics enabling the widest variety of applications in any academic field.

Uninterrupted Productivity

The STUDIO allows for around-the-clock non-stop printing so students can schedule print projects back-to-back and experiment efficiently even during the busiest periods.

Training and eLearning Platform

Students have complete access to online courses on the BigRep ACADEMY and in-person training from fundamentals to expert-level in 3D printing.

Space Conscious Machine Design

Built with a sleek body, the STUDIO is at home in any workspace. The machine runs on a convenient standard electrical outlet and has relatively low power consumption.

Intuitive 3D Print Software

Easy-to-use cutting-edge software suite gives students complete control over the print process, from design to print monitoring: BLADE, FLOW, and CONNECT.

Large-Format 3D Printing Applications Across Different Academic Fields

The natural intersection between the STUDIO and education lies in the shared focus on large-scale experimentation, critical thinking, and creativity. The 3D printer imparts practical learning by being a testbed for experimentation, prototypes, physical models, and real-world applications.

The most common educational fields that benefit from the STUDIO’s large-scale capabilities are:

1. Engineering

The significant advantage of the STUDIO for engineering and advanced manufacturing students is its ability to effortlessly print large parts with complex geometries. Designs that would be challenging or even impossible to build with traditional manufacturing methods are second nature for the 3D printer.

Engineering students can quickly test, iterate, and refine their ideas and experiment with different filaments thanks to the open material system. They can gain insight into how material properties influence design and how manufacturing processes impact the final product. This experiential learning helps students develop an intuitive understanding of materials science and manufacturing principles, equipping them with valuable skills for their future careers.

Here are some of the use cases of Universities employing BigRep 3D printing systems in their research labs.

Helmut Schmidt University's Eleven-O-Six Racing Team 3D printed the steering wheel, entire bodywork, and a nose cone prototype.

High-performance car production process
Eleven-O-Six Racing Team, a motorsport team at Helmut Schmidt University in Hamburg, Germany uses a BigRep 3D printer to see what it could bring to their high-performance car production process.

Prof. Dr.-Ing Jens Wulfsberg, the Chair of Production Engineering (LaFT) and leader of the project underlines a key advantage of their BigRep 3D printer:

"Using a BigRep 3D printer is a fast solution to produce a fast car because we have short cycles for optimizing the parts. In every iteration cycle, the car is better, and faster. This is one of the direct consequences of using the machine."

Rapid prototypes
Dr. Mario Oertel and his team at the advanced hydraulics engineering lab at Helmut Schmidt University are transforming weir designs with BigRep 3D printing systems.

End-use parts
Aalborg University Engineers 3D printed a functional bicycle frame in one go.

At Aalborg university, a fully functional bicycle frame was 3D printed, thanks to the BigRep 3D printer's large build volume.

Aerospace engineering
Aix-Marseille Université, one of the largest universities in France, developed a unique accredited degree program in aerospace engineering with BigRep 3D printing systems.

Using their BigRep 3D printer, Aix-Marseille’s technical aeronautical training school, POLYAERO introduced 3D printed mockup parts for an ideal training solution.

2. Sciences

Thanks to the large-build volume, the STUDIO can create anatomically accurate representations for biology and medicine students ensuring a realistic and immersive learning experience. The 3D printer can play a crucial role in medical device development, allowing researchers to prototype and test cutting-edge healthcare solutions.

The other area that additive manufacturing contributes significantly is in the visualization of concepts. Beyond healthcare and biology, they support environmental studies and geoscience research by creating models for studying ecosystems, geological formations, and natural phenomena.

The STUDIO can easily create complex components and prototypes for advanced physics research projects tailored to specific objectives. Students can experience experimental design, data collection, and analysis. Be it fabricating models that are tested by being subjected to natural forces, or designing innovative sensors, students can leverage the capabilities of FFF 3D printing to push the boundaries of scientific exploration and discovery.

The 3D-printed rotor blades at TU Berlin designed by Jörg Alber, and Laurin Assfalg with a BigRep machine.

TU Berlin’s Ph.D. student, Jörg Alber, and Master’s student, Laurin Assfalg, 3D printed a wind turbine rotor blade to experiment, evaluate, and improve its performance. By creating and optimizing rotor blades on a smaller scale with BigRep’s 3D printer, they could explore different infills, shapes, and materials and test them against simulated real-world conditions.

Laurin Assfalg:

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

3. Art

In art and design education, the STUDIO empowers aspiring artists with the freedom and practical skills needed to breathe life into their creative visions. Students can explore new techniques and experiment with materials, overcoming the limitations of traditional art mediums. Some of the areas where the 3D printers give the students a leg-up are with props and special effects, fine art creation, sculptures, installations, and art preservation.

The machine’s high level of precision helps students create intricate artwork, allowing them to delve into digital fabrication techniques and integrate technology into mixed-media art projects. Welly Fletcher, an Assistant Professor of Sculpture in the Department of Art at the University of New Mexico, built a bridge to prehistoric cave art with a massive 3D printed mixed-media lion-like figure with a BigRep printer.

Welly Fletcher’s sculpture ‘Trans Time’, an abstract depiction of a lion-like animal printed using a large-format BigRep 3D printer.

4. Architecture and Construction

Studying architecture and construction at a university with access to a large-scale FFF 3D printer offers students the opportunity to prototype their designs at scale. This helps with a detailed analysis of spatial relationships, structural integrity, and design aesthetics of the building. The physical model can be quickly iterated to find the perfect solution to architectural challenges.

From complex architectural features to intricate building elements, integrating a STUDIO in the process fosters interdisciplinary collaboration and innovation. Architecture and construction students can collaborate on projects that combine architectural principles with engineering expertise.

The elaborate, contemporary “Ancora Villa” printed on a BigRep printer, is a complex architectural design with a fragile overall structure and many highly intricate details.

BigRep 3D Printed an elaborate architectural model, Villa Ancora, in 1:50 scale in just 5 days.

5. Archaeology and Paleontology

FFF 3D printing can turn back time by recreating lifeforms that have gone extinct and artifacts that have been damaged or lost forever. The physical models are profoundly engaging, offering an unparalleled experience by allowing students to learn about the past by holding it in their hands. Creating singular pieces of small to large scale parts comes easy for the STUDIO and students have a wide variety of materials to choose from. Post-processing techniques like painting and wrapping the part ensure a more realistic representation.

CDM STUDIOS in Australia 3D was commissioned to create sculptures and models of dinosaurs and extinct sharks on short notice. With a BigRep 3D printer, they were able to accurately recreate 110 models in just 9 months.

A shark model 3D printed on a BigRep 3D printer by CDM:Studio.

6. Product Design

The iterative nature of 3D printing allows students to test and refine their ideas, gaining valuable insights into form, function, and manufacturability. By experiencing the entire design cycle—from concept development to prototyping—students develop critical problem-solving skills and design thinking methodologies.

The STUDIO enables the intersection of design, engineering, and materials science by collaborating with peers from diverse backgrounds to tackle complex design challenges. Through this collaborative approach, students gain a deeper understanding of the multifaceted nature of product design and develop the ability to integrate technical, aesthetic, and user-centered considerations into their designs.

Next-Gen AM Technology for Next-Gen Graduates

The STUDIO provides a solution for educational institutions that’s equal parts reliable and open for experimentation, engineered with state-of-the-art technology trusted by industry leaders. The 3D printer ensures successful research outcomes by printing high-accuracy parts with an open material platform rooted in a user-friendly, professional-grade full-solution AM eco-system.

In today's competitive job market, hands-on experience with professional 3D printers provides students with a valuable edge, offering a tangible representation of their ideas and enhancing the learning process. Prepare students for the real world and set them up for successful careers in any field, all within an accessible price range and unlimited experimental opportunities.

Want to learn more about how Universities are upgrading education with 3D printing?

In this webinar, we discuss with some of the top universities, the projects and research they’ve conducted using large-scale 3D printing.

REGISTER FOR THIS WEBINAR TO LEARN HOW

3D printers support scientists and students conducting research in universities
AM is crucial in fast-paced experimentation and rapid iteration
To unleash creativity through AM technologies
3D printers are an ideal tool in educational institutions to test new ideas.

INSPIRE STUDENTS & INNOVATE FASTER: INTEGRATING LARGE-FORMAT 3D PRINTING IN UNIVERSITIES.

Professional 3D Printer

Graduate from Desktop. Get Industrial.

With 10 times the build volume compared to desktop 3D printers, the STUDIO is your gateway to large-scale industrial manufacturing.

Key Features

Enclosed 250 Liters Build Chamber: 1000 x 500 x 500 mm build volume for large 3D prints from a machine that easily fits in most work spaces.
Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 per hour.
Heated Print Bed (Up to 100 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
Large Parts with Fine Detail: Layer heights from 0.1 to 0.6 mm let you achieve small details on large prints, without compromising on printing speed.

Key Features

Enclosed 250 Liters Build Chamber: 1000 x 500 x 500 mm build volume for large 3D prints from a machine that easily fits in most work spaces.
Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 per hour.
Heated Print Bed (Up to 100 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
Large Parts with Fine Detail: Layer heights from 0.1 to 0.6 mm let you achieve small details on large prints, without compromising on printing speed.

Explore the STUDIO

Graduate from Desktop. Get Industrial.

With 10 times the build volume compared to desktop 3D printers, the STUDIO is your gateway to large-scale industrial manufacturing.

Enclosed 250 Liters Build Chamber: 1000 x 500 x 500 mm build volume for large 3D prints from a machine that easily fits in most work spaces.
Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 per hour.
Heated Print Bed (Up to 100 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
Large Parts with Fine Detail: Layer heights from 0.1 to 0.6 mm let you achieve small details on large prints, without compromising on printing speed.

Explore the STUDIO

About the author:

" />

Natasha Mathew

Copywriter

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

Natasha Mathew — Thu, 18 Apr 2024 12:57:22 +0000

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

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

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

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

The Form is More Than Function

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

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

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

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

Large Scale Printing Creates Unique Design Possibilities

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

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

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

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

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

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

says Wang.

Responding to Customer Demand

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

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

3D Printing in a Circular Economy

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

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

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

A Future Filled with 3D-Printed Possibilities

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

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

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

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

Want to Learn More about 3D Printing Bespoke Furniture?

Download the eBook, RH-Engineering & manoFigura 3D Print Luxury Furniture.

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

Read this additive manufacturing case study to learn:

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

HOW RH-ENGINEERING & MANOFIGURA 3D PRINT LUXURY FURNITURE

About the author:

" />

Patrick McCumiskey

Author

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

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

Natasha Mathew — Thu, 28 Mar 2024 15:44:24 +0000

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

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

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

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

Embracing the Open 3D Printing System

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

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

Dr. Dong explains,

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

Cost and Time Savings with Rapid Prototyping

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

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

says Dr. Dong.

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

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

Large-Scale 3D Printing for Heavy-Duty Trucks

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

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

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

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

The Future of 3D Printing in Custom Commercial Vehicles

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

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

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

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

Learn how large-format 3D printers give companies the flexibility and versatility to iterate fast, produce faster, and get to market faster, all while reacting to challenging customer requirements on short notice.

REGISTER FOR THIS WEBINAR TO LEARN ABOUT

Large-format 3D printing and customer applications
How BigRep is supporting the trucking industry
Customer success stories from prototyping to end use parts
Benchmark breakdown

IMPROVE TIME TO MARKET FOR CUSTOM COMMERCIAL VEHICLES

About the author:

" />

Patrick McCumiskey

Author

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

Natasha Mathew — Fri, 09 Feb 2024 16:03:42 +0000

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

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

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

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

Adding 3D Printing to the Palette

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

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

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

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

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

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

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

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

Large-Format 3D Printing for Sizeable Sculptures

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

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

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

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

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

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

Fletcher elaborated.

Analog Roots in a Digital World

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

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

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

Whether it's fine art, museum displays, or innovative installations, BigRep 3D printers are essential for large-scale creative projects.

Unlimited Creativity in 3D Printed Exhibitions

Your imagination is the only limit to what you can create with a 1m3 building volume of BigRep 3D printers
Keep on schedule to manage tight deadlines by avoiding manual labor and outsourcing
3D printing can reduce costly material waste and replace expensive skilled labor

LEARN MORE

About the author:

" />

Patrick McCumiskey

Author

3D Printing Powers Wind Turbine Research at TU Berlin

Natasha Mathew — Fri, 12 Jan 2024 17:01:50 +0000

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

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

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

Laurin Assfalg:

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

3D Printing Breathes Life into the Blades

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

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

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

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

Structural Considerations: Infill and Material

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

1. Gyroid Infill

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

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

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

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

2. BigRep’s Industrial Grade PRO HT

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

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

Putting the Blades to the Test

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

1. Structural Testing

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

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

What are Ultimate Load Cases (ULCs)?

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

What is a Universal Testing Machine?

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

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

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

2. Wind Tunnel Tests

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

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

The Future of Wind

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

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

Want to Learn More About Gyroid Infill?

Explore the innovative use of gyroid structures in wind turbine manufacturing and biomedical applications with expert Jörg Alber from TU Berlin. Don't miss out, watch the webinar now:

THE 3D-PRINTED GYROID: IMPROVING STRUCTURALLY DEMANDING APPLICATIONS

About the author:

" />

Natasha Mathew

Copywriter

User Stories – BigRep Industrial 3D Printers

Large Scale 3D Printing Shines New Light on Laser Research

The Challenge: Customizing Experiment Environments

Large Scale 3D Printing for Laser Research

The Chamber Design

Reasons for Going Big with 3D Printing

WHY THE BIGREP VIIO 250

Advanced Automation

Enclosed Build Chamber

Dual Extruders Print with Different Materials

Large-Scale Build Volume

Precise Parts

Ease of Use

Seeing Optical Research in a New Light

About the author:

Natasha Mathew

Related Content

Inspire Students and Innovate Faster: Integrating Large-Format 3D Printing in Universities

3D Printing Powers Wind Turbine Research at TU Berlin

Integrating CAD and Additive Learning into General Education

How 3D Printing is Paving the Way for Grading Contractor, C.J. Moyna & Sons

UPGRADING OPERATIONS WITH THE BIGREP PRO

Massive Size

Speed & Accuracy

Open Material Platform

Automation Features

Driving the Future

Want to learn how Industries are expediting Product Development with 3D Printing?

Industrial Quality Meets Cost Efficiency. Complex Parts in Large Scale.

Industrial Quality Meets Cost Efficiency. Complex Parts in Large Scale.

About the author:

Yücel Uzunoglu

3D Printed Dragon Brings in the Chinese New Year

The Challenges Artistic Spaces Faced

BigRep's Solution

“This was our first experience working with a large-scale 3D printer, and the entire process exceeded our expectations. Once we had the model in the slicer, it was easy to write the code and watch it print.”

“The BigRep ONE ran nonstop for three days without any issues. Thanks to ELK3D's onsite training, our team confidently use the machine, we simply hit the start button and get on with our tasks while the machine takes care of the part.”

Chinese New Year and the Dragon Project

“We partnered with BigRep because of their reliability, quality, advanced technology, and the dedicated team behind it. This collaborative environment enabled us to achieve success with Artistic Spaces, James, and his team.”

The Transformation

The Results

Limitless Creativity

Large-Scale Innovation. Limitless Creativity.

Large-Scale Innovation. Limitless Creativity.

About the author:

Michelle Green

About the author:

Jason Tzintzun

The BigRep IPSO 105 Futureproofs Outdoor Fiber Cabinets

What are Fiber Connection Cabinets (FCC)?

Challenges with Traditional Manufacturing

Benefits of a Large-Scale High-Temp 3D Printer

SCALING UP WITH THE HIGH-PERFORMANCE BIGREP IPSO 105

Large-Scale Innovation

High-Temperature Applications

Open Material Platform

High Cost and Time Savings

Sichert’s Applications with the IPSO 105

Future-Proofing Outdoor Cabinets

Want to learn how Industries are expediting Product Development with 3D Printing?

Maximum Performance. Unbeatable Price.

Maximum Performance. Unbeatable Price.

About the author:

Natasha Mathew

3D Printed Chandelier, The Hedron, Outshines Conventional Ceiling Lights

Ben Mickus, an award-winning designer and practicing architect, designed and 3D printed “Hedron,” a pendant that’s light years ahead of modern chandeliers.

The Genesis of Hedron

3D Printing Illuminates the Path

Design Elevated by Functionality

A Bright Future Ahead

Want to Learn More about 3D Printing Bespoke Furniture?

About the author:

Natasha Mathew

3D Printing in Education: The BigRep STUDIO Takes Learning Out of the Box

Join the Ranks of Top Universities by Integrating Large-Scale 3D Printing into Your Curriculum

WHY THE STUDIO IS THE BEST-IN-CLASS EDUCATIONAL TOOL

A Generous Build Volume

A Safe, Fully Enclosed Build Chamber

Open Material Platform

Uninterrupted Productivity

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

WHY THE STUDIO IS THE BEST-IN-CLASS
EDUCATIONAL TOOL