Large-format 3D printing at Formnext: BigRep showcases new systems and materials

BigRep is using Formnext 2025 in Frankfurt to present its updated portfolio for large-format FFF 3D printing. In Hall 12.1, Booth E129, the company is demonstrating the BigRep ONE.5, the VIIO 250, as well as the DRYCON and IPSO 105 peripheral systems. In addition, BigRep is showcasing new filaments based on recycled material that are specifically designed for long build jobs in industrial environments.

The BigRep ONE.5 extends the well-known one-cubic-meter system with functions from the latest machine generations. At its core is the PEX2 extruder, designed for high melt throughput and capable of producing two parts in parallel in Twin Mode, which is particularly beneficial for series production of identical components. A semi-automated print bed with magnetic switchplates is intended to simplify switching between different build plates and materials and enables tailored adhesion and surface properties.

The VIIO 250 targets users aiming for a more automated continuous operation. Its build volume of 1 × 0.5 × 0.5 meters is supported by features such as automatic bed mapping, filament flow control and x/y calibration. The Smart Manufacturing Extruders process engineering thermoplastics and carbon-fiber-reinforced filaments up to 350 °C. For material and part handling, DRYCON provides two chambers for drying, storage and thermal post-treatment at temperatures up to 180 °C, for example to improve dimensional accuracy and heat deflection temperature.

The IPSO 105 will be shown in Hall 11.1 at the Endless Industries booth in a configuration for continuous fiber reinforcement. With a heated build chamber and extruder temperatures up to 450 °C, the system targets materials such as PC, PEKK and PEKK-CF. In parallel, BigRep is introducing the rPLA and rPETG filaments, which are made from post-industrial scrap and available in large spool sizes; a smart buoy demonstrator for water quality monitoring printed with rPETG illustrates a possible application.

In addition, BigRep is developing a pellet extrusion option together with Massive Dimension, based on the MDX10 unit for the ONE, which is slated for 2026. Pellet printing is expected to enable higher throughput and lower material costs, especially for very large parts. Practical examples from aerospace, marine applications and the design sector at the trade show booth illustrate how large-format FFF printing, material management and post-processing can be combined into an end-to-end manufacturing solution.