BigRep & Endless Industries Introduce Large-Format Continuous Fibre Reinforcement 3D Printing Capability

Why It Matters

By lowering the cost and complexity of large‑scale composite printing, the partnership opens industrial 3D printing to aerospace, medical and tooling sectors that previously required multi‑million‑dollar investments.

Key Takeaways

• 20× stronger parts than standard thermoplastics.
• 100 °C build chamber enables high‑temperature thermoplastics.
• Akio software optimizes fibre placement for load‑bearing components.
• First large‑format continuous‑fibre printer at production‑grade cost.
• Global rollout starts DACH 2026, expands 2027‑28.

Pulse Analysis

Continuous‑fibre additive manufacturing has long been a niche capability, limited to small‑bed printers or expensive, labor‑intensive lay‑up processes. The technology promises the stiffness and weight savings of carbon‑fiber composites while retaining the design freedom of 3D printing, yet high entry costs and complex workflows have kept most manufacturers at bay. Recent advances in print‑head design and material science are finally aligning with market demand for faster, more sustainable production of load‑bearing components.

The BigRep‑Endless collaboration tackles those barriers head‑on. By embedding Endless’s proprietary print heads, high‑temperature thermoplastics, and the Akio optimisation software into the IPSO 105’s 1 meter‑plus build volume, the system can fabricate parts that are up to twenty times stronger than conventional printed plastics. The 100 °C chamber stabilises material flow, reducing warpage and enabling aerospace‑grade polymers such as PEKK and PEEK. Moreover, the integrated software automatically generates fibre paths that maximize stiffness while minimizing waste, turning what was once a craft‑based operation into a repeatable production process.

For end users, the impact is immediate. Aerospace manufacturers can now produce lightweight brackets and interior structures without costly tooling, while medical device firms gain a rapid‑prototyping route for custom orthotics and prosthetics that meet stringent load requirements. The announced DACH launch in mid‑2026, followed by a phased global rollout, signals that the market is moving beyond pilot projects toward full‑scale adoption. Competitors will need to match this blend of size, strength, and cost efficiency, or risk losing ground in a segment poised for rapid growth as industries chase lighter, stronger, and more agile supply chains.