BigRep, a German manufacturer specializing in large-format fused-filament fabrication (FFF) systems, presented several new products and technologies at Formnext 2025 in Frankfurt, held from November 18 to 21. At Hall 12.1, Booth E129, the company exhibited its latest large-scale 3D printers—the ONE.5, VIIO 250, and DRYCON—alongside new sustainable filaments and a pellet-extrusion system developed in partnership with Massive Dimension.
New Additions to the Large-Scale Portfolio
The BigRep ONE.5 builds on nearly a decade of evolution from the company’s flagship large-format printer. It features a one-cubic-meter build volume and an upgraded PEX2 extruder with up to 40 percent higher flow rate than its predecessor. The extruder supports a wider range of materials and includes a Twin Mode for simultaneous dual-extruder printing, increasing throughput on large components. A semi-automatic magnetic bed system with SWITCHPLATE surfaces improves material compatibility and reduces setup time.
The BigRep VIIO 250 introduces a fully automated architecture designed for continuous manufacturing. Its 1 × 0.5 × 0.5 meter build area integrates automated bed mapping, filament flow-rate adjustment, and X/Y calibration. Dual Smart Manufacturing Extruders (SMX) operate at up to 350 °C, enabling the processing of engineering-grade and carbon-fiber-reinforced materials. An Infinity Box module detects depleted spools during printing and automatically loads new filament to maintain uninterrupted operation.
The DRYCON system combines drying, storage, and annealing within two chambers that heat to 180 °C. Each chamber can dry and anneal parts to improve mechanical strength, thermal resistance, and dimensional accuracy. Four filament outlets feed material directly into connected printers, minimizing handling during production.
Demonstrating a Multi-Scale Approach
At the Endless Industries booth in Hall 11.1, BigRep technology was also featured through the IPSO 105, configured for continuous-fiber printing. Positioned between desktop and industrial systems, the IPSO 105 provides a 0.4 × 0.6 × 0.44 meter build volume, a 100 °C chamber, a 180 °C print bed, and a 450 °C extruder. The printer processes high-performance polymers including PC, PEKK, and PEKK-CF, and uses automated calibration functions for rapid startup.
BigRep additionally introduced two sustainable filaments, rPLA and rPETG, both produced entirely from post-industrial residual waste (PIR). The materials are optimized for large-format printing with spools up to 8 kg, supporting long production runs with reduced waste. A 3D printed smart buoy made from rPETG was displayed at the booth to illustrate the material’s durability and use in water-quality monitoring.
Pellet-Extrusion Collaboration and Industrial Use Cases on Display
To expand its production capabilities, BigRep collaborated with Massive Dimension, a U.S.-based developer of pellet-extrusion systems, on the integration of the MDX10 extruder for the BigRep ONE series. The project, in its final development phase, targets commercial availability in mid-2026. Pellet-fed extrusion provides higher deposition rates for very large parts while lowering raw-material costs compared with filament. The system is designed for industrial environments requiring high throughput and reduced print times.
Several industrial partners demonstrated components produced with BigRep printers. Airbus Helicopters presented a PA12 carbon-fiber attachment used in a rotating assembly jig. SFM Technology, a supplier to aerospace and defense firm Leonardo, exhibited a HI-TEMP CF helicopter-blade restraint cradle designed for maintenance operations. NewsFender showcased customizable thermoplastic polyurethane (TPU) marine fenders fabricated on BigRep systems. Artists Sven Sauer and Chris Iwasjuta displayed a life-size 3D printed soldier figure, demonstrating the geometric precision achievable at meter-scale dimensions.
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Featured photo shows a BigRep engineer holding a large-format 3D printed component produced on the BigRep ONE.5 system. Photo via BigRep.
