Berlin-based 3D printer manufacturer BigRep GmbH and Technical University of Berlin spin-off Endless Industries have entered a long-term global technology partnership focused on bringing continuous fiber reinforcement to large-format additive manufacturing (LFAM) at an industrial scale.
The announcement, made on April 30, 2026, follows two years of joint development and marks the beginning of a commercial rollout phase.
“After two years of joint development, we’ve reached a level of technological maturity that will redefine the role of continuous fiber in industrial 3D printing. Now is the right time to bring this innovation to market,” said Thomas Janics-Jakomini, CEO of BigRep.
Two Years of Development, One Integrated Platform
The foundation of the partnership is the integration of Endless Industries’ continuous fiber system into the BigRep IPSO 105, a high-temperature, large-format industrial printing platform. The combined solution produces mechanically reinforced components with continuous carbon fiber, offering strength levels up to 20 times higher than unreinforced thermoplastics, while keeping costs substantially below those of traditional automated fiber placement systems.
Each company contributes a distinct layer of the stack. Endless Industries brings a vertically integrated approach covering print heads, materials, and its proprietary “Akio” software platform for fiber architecture optimization. BigRep contributes industrial hardware, a global service network, and an established partner ecosystem. The result is a unified system designed to reduce complexity and support repeatable, production-grade output.
The platform supports high-performance and high-temperature thermoplastics, build chamber temperatures up to 100°C, and continuous fiber integration without modifications to existing workflows. All printed components remain fully recyclable, distinguishing the process from thermoset-based alternatives.
What the Technology Makes Possible
The integrated system opens economically scalable production of large-format composite parts in PETG, Polyamide, and Polypropylene across several industrial sectors. In manufacturing environments, it enables high-strength jigs and fixtures as direct replacements for metal or CNC-machined tooling.
In aerospace, it supports lightweight structural components from high-performance materials. In medical and orthopedic applications, it allows production of customized load-bearing devices including orthoses and prosthetic components.
Stephan Knopf, CEO of Endless Industries, said: “Large-format composite manufacturing has traditionally been craft-based or required multi-million-dollar investments. This partnership removes those constraints. Customers now gain access to a production-ready system for high-strength parts without the traditional barriers to entry.”
Phased Commercial Rollout Through 2028
The commercial phase launches in Summer 2026 with joint sales activities in Europe, initially targeting the DACH region, Germany, Austria, and Switzerland. International expansion is planned for 2027 and 2028, extending through BigRep’s global partner network across Europe, the United States, Asia, and Australia. Both companies have committed to scaling their sales, service, and technical expertise infrastructure to support adoption across markets.
Closing the Gap Between Fiber Strength and Industrial Scale
Continuous fiber composites have long delivered exceptional mechanical performance, but bringing that capability to large-format, production-grade output has historically required either highly specialized expertise or capital investment that put it out of reach for most manufacturers. That is the gap BigRep and Endless Industries are targeting: a fully integrated system that removes the traditional barriers without sacrificing industrial performance.
The defense sector has been among the most active in validating this direction. Continuous Composites was awarded a multi-year, multi-million-dollar contract from the U.S. Air Force to advance high-performance composite materials using its CF3D technology, a robotic process that deposits continuous dry fibers with snap-curing resin to produce near-net-shape aerospace components.
Elsewhere, Rocket Lab deployed a 90-ton automated fiber placement machine from Electroimpact capable of laying down 100 meters of continuous carbon fiber per minute, cutting a stage 2 dome build from several weeks to a single day.
What these deployments share is a common constraint: access to the technology has remained selective, tied to defense budgets or niche expertise. BigRep and Endless Industries are positioning their partnership as the commercial answer, a production-ready system for high-strength, large-format composite parts that manufacturers outside of defense programs can actually reach.
3D Printing Industry is inviting speakers for its 2026 Additive Manufacturing Applications (AMA) series, covering Energy, Healthcare, Automotive and Mobility, Aerospace, Space and Defense, and Software. Each online event focuses on real production deployments, qualification, and supply chain integration. Practitioners interested in contributing can complete the call for speakers form here.
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Featured image shows BigRep and Endless Industries Bring Continuous Fiber Reinforcement to Large-Format 3D Printing. Photo via BigRep.
