Industrial large-format 3D printing for complex parts

The BigRep Pro is a fully enclosed industrial 3D printer with a 1 cubic metre build volume for producing full-scale large parts. It is built to deliver functional prototypes, factory tooling, patterns, moulds, and end-use parts with a workflow designed for faster and more cost-efficient manufacturing.

What the BigRep Pro delivers in production

Built for productivity throughout all stages of manufacturing, the BigRep Pro gives designers, engineers, and manufacturers an agile, easy-to-use solution for large-scale part production. The system is designed to help teams produce faster and reduce the dependence on slower, outsourced methods.

Supported by the Precision Motions Portal, a durable custom-built gantry, and Bosch Rexroth CNC components, the printer is engineered to maintain speed, precision, and quality. BigRep JUMPSTART adds a hybrid software-hardware workflow that reduces setup complexity and helps users start printing with less manual intervention.

Industrial applications for large-format manufacturing

The BigRep Pro is built for production environments that need full-scale parts, on-demand manufacturing tools, and shorter iteration cycles. Its enclosed build platform, large volume, and material support make it suitable for multiple industrial workflows.

Full-scale functional prototypes

• Produce full-scale functional parts from the alpha phase through to zero series.
• Learn faster and iterate designs in hours and days instead of weeks and months.
• Avoid expensive outsourced production and traditional slower processes.

Tooling, jigs, and fixtures

• Customise tools for a precise fit, lower weight, and improved ergonomics.
• Reduce lead times with on-demand production and avoid outsourcing logistics.
• Lower production and material costs with optimised tooling designs.

Patterns and moulds

• Replace high-cost patterns and moulds made from expensive materials.
• Accelerate design iteration, product testing, and production preparation.
• Minimise outsourcing, external logistics, and supply chain dependence.

End-use parts

• Produce small-series and unique parts without added tooling costs.
• Manufacture on demand to reduce inventory and warehousing requirements.
• Cut lead times to support faster product delivery.

JUMPSTART workflow for easier setup and consistent first layers

BigRep JUMPSTART is a hybrid software-hardware solution designed to simplify operation on the BigRep Pro. It combines the SWITCHPLATE® removable print surface, the LOCKSTAGE extruder mounting system, and the MXT® Control System to reduce manual setup steps and improve repeatability.

Material support for industrial applications

The BigRep Pro is designed to print engineering-grade materials, carbon fibre-reinforced materials, bio-polymers, and water-soluble support materials. This material range supports both functional manufacturing and more application-specific part requirements.

BigRep develops and certifies filaments specifically for the BigRep Pro, and the printer is also third-party compatible. That gives users the flexibility to work with BigRep materials as well as other filament brands, depending on application needs.

Large-format motion system engineered for speed and accuracy

High accuracy at high speeds

The Precision Motions Portal

The BigRep Pro’s 1m3 build volume is supported by a durable custom-built gantry engineered for high speed, fast acceleration, and accuracy. The robust frame is designed to eliminate vibrations during 3D printing, supporting fast but precise extruder movement along a reinforced carriage system.

Powered by Bosch servo motors with integrated encoders, the printer calculates the real-time location of the print head to self-monitor position accuracy. This motion architecture is built for reliable large-format output where both throughput and dimensional control matter.

Direct drive extrusion for precise fibre-ready printing

Fast, precise, and fibre-ready extrusion

The Advanced Capability Extruder

BigRep’s Advanced Capability Extruder (ACE) expands the material capabilities of the BigRep Pro while maintaining reliable print quality, speed, and precision. As a direct drive extruder, ACE is equipped for fibre-reinforced materials such as BigRep HI-TEMP CF.

ACE enables the production of large-format strong parts and is stated to print 50% faster than other large-scale printers. This combination of direct drive control and reinforced material capability supports industrial applications where strength and part size are both important.

Dry filament storage for consistent material performance

Airtight filament chamber

The dry material storage system

The BigRep Pro includes an environmentally sealed filament chamber with a two-spool capacity to keep materials dry in a consistently temperature- and humidity-controlled environment. This storage design supports engineering-grade materials and water-soluble materials that require stable conditions.

Even when the printer is powered off, the airtight material storage is designed to maintain material quality and reliability. For production users, that helps preserve print consistency between jobs and reduces material handling issues in demanding environments.