BigRep Debuts Large-Format 3D Printing Updates

BigRep, a company focused on large-format additive manufacturing, is debuting two major advances at RAPID + TCT 2026 (Booth #2355, April 14–16, Boston): the new BigRep ONE.5X — a fully automated evolution of its 1-m-cubed 3D printer — and a co-development partnership with Massive Dimension that brings pellet-based extrusion to the BigRep platform for the first time.

Smart Automation

The new BigRep ONE.5X introduces advanced automation, a redesigned user interface, and smarter print performance.

“The ONE.5X represents everything we've learned from over a decade of industrial large-format 3D printing, as well as global customer feedback. All of that is distilled into a machine that delivers consistent results, regardless of an end-user’s experience level.”

— Jeff Olson, President, BigRep America, Inc.

The ONE.5X retains the dual PEX2 extruders, material compatibility, and flexible SWITCHPLATE print bed options from the previous ONE.5, while adding a new generation of features.

The ONE.5X introduces a new Human Machine Interface (HMI) — the same intuitive UI first seen on the BigRep VIIO 250. Over-the-air (OTA) software updates are also new to the ONE platform.

Advanced Automation 

The ONE.5X is engineered to reduce manual user intervention:

• XYZ autocalibration handles machine setup automatically, eliminating manual calibration steps.
• Auto-sequential printing detects available space on the print bed and starts the next queued job automatically — no operator required.
• Adaptive bed mesh leveling maps the print surface before every job, compensating for any unevenness to nail first-layer adhesion across the full bed.
• Relay Mode automatically switches to the second extruder if the first runs out of material, keeping long print jobs running to completion without operator intervention.

Built for Speed 

• Maximum print speed of up to 250 mm/s.
• A new pressure advance algorithm regulates material flow during acceleration and deceleration, eliminating corner bulges.
• Vibration compensation actively counteracts frame resonance at higher print speeds.

BigRep & Massive Dimension Collaborate

In other news, through a new co-development partnership with VT-based Massive Dimension, BigRep is expanding into pellet-based large-scale extrusion by integrating the company’s new MDX extruder into the BigRep ONE platform.

Weighing 25% lighter than its predecessor and built with 40% fewer parts, the MDX from Massive Dimension is compact and designed to be serviced fast, making it an ideal fit for the BigRep ONE. 

By combining Massive Dimension’s extrusion expertise – backed by more than a decade in large-format additive manufacturing – with BigRep’s industrial-grade printers and global sales and service network, the two companies aim to support customers looking for faster printing, lower material costs, and greater production flexibility, the companies note.

BigRep and Massive Dimension are targeting availability by end of 2026. The MDX extruder will be on display at RAPID + TCT, Booth #2355.

Sources: Press materials received from the company and additional information gleaned from the company’s website.