BigRep ONE.5X Unlocks Hands-Off Large-Scale 3D Printing

For over a decade now, Berlin-based BigRep has been the go-to hardware supplier for large-scale FDM 3D printing. It’s no surprise why: the company’s flagship BigRep ONE 3D printer, with a build space of one cubic meter, set the standard for large-format polymer AM upon its release in 2014 and has since empowered users from across diverse segments, from education to aerospace, to create big—really big—parts. 

As the BigRep ONE has shaped the evolution of large-format 3D printing applications, BigRep has also continued to evolve its technology, continually upgrading and developing both hardware and software for improved print results and greater productivity. This commitment to growth has culminated in the launch of the BigRep ONE.5X, the latest generation of its flagship solution, which delivers the same large build volume with greater intelligence and automation. 

As we’ll see, the BigRep ONE.5X is unlocking greater productivity in terms of print speed, machine up times, and consistency. Not only that, the 3D printing solution is built for autonomous, hands-off 3D printing, ensuring that the printing process remains easy and accessible for all types of users.  

Building on Success 

Before we explore the many new features and upgrades in the BigRep ONE.5X, let’s take a quick look at the generations of BigRep ONE that came before and the legacy of the BigRep name.  

For this we’ll have to rewind back to February 2014, when the company announced—for the very first time—its large-scale 3D printer the BigRep ONE. At the time, the response within the additive and broader manufacturing markets was one of enthusiasm, for this was the biggest FDM 3D printer to ever launch. Today, the BigRep ONE system (now on its fifth generation) has a global installed base of over 500 and is a key manufacturing solution in the creation of prototypes, tools, and end-use parts in education, aerospace, architecture, automotive, defense, design, and more.  

Over the years, the BigRep ONE solution has always maintained its key strengths: its one-cubic-meter build volume, its open source materials, and its user accessibility. At the same time, continuous upgrades have expanded and maximized these strengths. For instance, the introduction of dual PEX2 extruders in 2024 enabled the printing of more materials as well as significantly higher flow rates. Remote printing capabilities also helped to increase productivity for users by enabling them to manage their print jobs from anywhere.    

The latest generation of its flagship system, the BigRep ONE.5X, takes the system’s large-format printing capabilities to another level, where hardware upgrades and intelligent tools come together for reliable, hands-off industrial AM.   

Maximizing Productivity with Automation 

The BigRep ONE.5X is at the cutting-edge of large-scale FDM 3D printing. With innovations carried over from BigRep’s fourth-generation system, the BigRep ONE.5, the new system builds on over 10 years of large-scale AM engineering.   

Among the innovations to be carried over are the aforementioned dual PEX2 extruders, which are more lightweight and faster than previous extruders. Notably, this extrusion system features a dual-drive feeding wheel that facilitates more precise and reliable printing even as flow rates are increased. The PEX2 extruders are also compatible with high-performance diamond nozzles, which makes it possible to print tough materials like fiber-reinforced and engineering thermoplastics. Other innovations from the preceding generation include BigRep’s SWITCHPLATE removable and flexible print bed surfaces, which come in a variety of coatings for different materials; and the Keep-Dry Box for filament storage and preservation.  

Now for the new. In the BigRep ONE.5X, BigRep has rolled out a host of automation-focused upgrades geared towards lights-off, round-the-clock printing.  

These upgrades include: 

• XYZ auto-calibration and adaptive bed mesh leveling for consistent first layers.
• A vibration compensation algorithm for cleaner, more accurate parts.
• An intuitive touchscreen interface driven byBigRep’sproduction OS architecture, that includes smart material build profiles and remote monitoring via BigRep CONNECT.
• Auto-sequential printing, a smart print queue function that automatically prints the next job in the queue (withsamematerial/nozzle settings) if there is room on the build platform.
• Relay mode, a new function where the 3D printer will use the backup extruder if the primary extruder runs out of filament (providing the material and nozzle match). 

This combination of upgrades has delivered measurable productivity improvements for BigRep’s large-format 3D printing, including up to 10 times faster print rates without sacrificing quality. And it’s not just faster print speeds that lead to productivity gains: with improved extrusion accuracy (particularly at corners and edges); higher print success rates thanks to auto calibration and SWITCHPLATE-improved adhesion; maximized platform usage with auto-sequential printing; and autonomous, hands-off 3D printing, the BigRep ONE.5X is BigRep’s most advanced, productive system to date.  

BigRep ONE.5X Switchplate. Source: BigRep

The new system also continues BigRep’s tradition of accessibility, with an improved user experience driven by more automation (i.e. less manual intervention requirements) and intuitive user interfaces. This allows more levels of users to 3D print large-scale parts, opening up the technology to more people and, ultimately, more ideas. 

Upgrading the BigRep ONEUpgrading the BigRep ONE 

In line with its accessibility ethos, BigRep is giving existing customers (specifically of the BigRep ONE.4 and the BigRep ONE.5) the ability to upgrade their systems with the ONE.5X Controls Upgrade Kit. New customers or those looking to expand their fleets of large-format 3D printers can also purchase the fifth generation system outright.  

Those interested in upgrading older generations of BigRep’s 3D printing technology can take their existing hardware to the next level in terms of motion control, automation, print accuracy, overall efficiency, and ease of use. The upgrade kit, which will be installed by BigRep-certified technicians, comes with a range of components, including a Mainboard Kreuzboard + CB-XB-MAIN, motor drivers, an integrated control system upgrade, pre-configured firmware package, and a bed probe sensor upgrade.  

Once installed, users will benefit from faster print speeds (up to 250 mm/s), greater precision for edges and corners, and improved motion control. Moreover, the combination of the intuitive interface, remote monitoring, and latest slicer iteration (Blade 5.16.0) means that users of all experience and skill levels can print high-quality parts with consistency and repeatability, whether it's a turbine prototype, a boat fender, or an art installation. 

BigRep, a Leader in Big PrintingBigRep, a Leader in Big Printing 

With new hardware and software upgrades, the BigRep ONE.5X represents where large-scale 3D printing is headed: towards greater productivity, automation, and accessibility. Moreover, BigRep’s commitment to evolving and improving its large-format 3D printing solution is in line with its commitment to its growing customer base. This is illustrated by the company’s upgrade offers, which enable customers to boost their existing hardware solutions without having to invest in a wholly new system.  

Ultimately, the BigRep ONE.5X delivers greater quality, productivity, and efficiency in large-format 3D printing for end users across industries like architecture, automotive, aerospace, defense, design, education, and even more.