Large-format 3D printing for full-scale parts and production workflows

The BigRep ONE.5X Professional 3D Printer is a large-format 3D printer built to produce full-scale parts, prototypes, moulds, and creative projects with a massive one-cubic-metre build volume. Designed as a reliable workhorse, the BigRep ONE combines robust construction, accessible operation, and high-flow extrusion for demanding professional use.

The award-winning BigRep ONE is positioned as an accessible large-format system and has nearly 500 systems installed worldwide. Designers, innovators, and manufacturers use the platform to bring large designs to life at scale.

Touchscreen controls for remote loading, monitoring, and print recovery

The machine's graphical user interface is built around an intuitive touch panel that simplifies day-to-day operation. The interface gives direct access to remote loading, webcam-based print progress checks, print parameter changes, and print recovery after a power failure.

These controls help reduce interruptions on long print jobs and make the printer easier to manage during large-format production.

Open industrial frame for access, visibility, and safe operation

The frame construction uses a robust open industrial design that keeps the print area easy to reach and easy to observe. Operators can monitor print quality without obstruction and access the print bed from three sides.

The enclosure supports a stable printing temperature while maintaining CE-compliant operator safety. This combination of accessibility and controlled conditions is useful for large parts that need regular observation.

Heated bed with SWITCHPLATE options and simplified calibration

The heated print bed uses magnetic SWITCHPLATE options to extend the material range and support strong adhesion across different materials. Two SWITCHPLATE variants are available as an add-on, allowing the build surface to be matched to application needs.

The printer also retains its integrated inductive sensor and semi-automatic bed levelling system to simplify platform calibration. This helps reduce setup effort on a machine designed for very large prints.

PEX2 extrusion for higher flow, lighter weight, and fibre-ready printing

The fibre-ready PEX2 extruder system is engineered for faster and more versatile material processing. Compared with the previous extruders, the new PEX2 units are 600 g lighter and deliver a 40% higher flow rate.

The BigRep ONE comes equipped with one BigRep fibre-ready Power Extruder (PEX2) with interchangeable 0.6, 1.0, and 2.0 mm nozzles. These nozzle options support either finer detail or high-flow additive manufacturing depending on the part requirements.

For broader material capability, the powerful dual-drive feeding wheel setup includes long-lasting, wear-resistant diamond nozzles for reliable printing with soft materials as well as carbon fibre-reinforced materials.

Protected filament storage for large spool capacity

The filament enclosure shields stored material from moisture and dust to help maintain stable print conditions. It fits all standard spool sizes, including two 8 kg spools, which is especially useful for large-format jobs that consume substantial material.

The Keep Dry Box Add-On also works with an out-of-filament sensor that pauses printing when a spool runs empty. This feature is particularly important on long prints, where replacing material without losing the job helps maintain workflow continuity.

Core performance highlights

• Print big: generous 1 cubic metre build volume.
• Print double: Twin Mode allows two parts to be printed at once.
• Print fast: average flow rate is 40% faster.

Large-format 3D printer features for production and prototyping

Massive build volume for geometrically complex parts

The BigRep ONE retains the one-cubic-metre build volume of its predecessor and is designed to produce massive 3D prints over 1000 x 1000 x 1000 mm in size. This scale makes the printer suitable for demanding and geometrically complex applications where smaller systems limit part size or require sectioning.

Large-format output allows parts to be produced in full scale, which can improve fit checks, form evaluation, and end-use preparation.

Safe and accessible print monitoring

The open design makes the print process easier to supervise throughout a job. Operators can inspect progress and print quality at any time, while the enclosure helps maintain a stable printing temperature and supports CE-compliant operator safety.

Print more materials faster

Dual PEX2 extruders increase throughput and support more advanced material strategies. The lighter design, higher flow rate, and Twin Mode operation make the system quicker and more cost-efficient for repeat production and larger parts.

Easy and intuitive operation

The touch-panel interface simplifies access to key printer functions, including remote loading, webcam-based progress monitoring, and print parameter changes. These tools make the machine easier to operate from anywhere during longer jobs.

Optimal print adhesion across material options

Magnetic SWITCHPLATE options expand the material range and provide strong adhesion for different materials. Combined with semi-automatic bed levelling, the bed system is designed to make preparation more consistent on large prints.

Secure and spacious filament management

The Keep Dry Box Add-On stores filament in protected conditions and accommodates all standard spool sizes, including two spools up to 8 kg. The added out-of-filament pause function is useful for uninterrupted handling of long-duration builds.

Extruder configurations for different workflows

The BigRep ONE can be configured in single, dual, or twin extruder modes to match budget, material needs, and production goals.

Single Mode for straightforward large-format printing

Single Mode is described as a robust solution at minimal cost and is well suited to beginners. In this setup, one extruder is used for both the model and the support material.

Dual Mode for support materials and mixed properties

Dual Mode adds a second extruder for water-soluble support filament or for combining two filaments with different properties. This configuration supports more complex applications and part geometries.

Twin Mode for duplicate part production

Twin Mode uses both extruders simultaneously to print two identical parts at once. According to the original product information, this can cut cost and time-to-part by 50% when producing duplicate components.

Use cases for architecture, tooling, prototypes, and education

Design and architecture

The BigRep ONE is used for fine art, museum displays, film props, and large creative installations where scale is a central requirement. Digitising fabrication opens more production possibilities for design teams working on custom, large-scale work.

Forms and moulds

3D printed patterns and moulds can replace expensive CNC-milled or hand-crafted traditional forms. For casting-related workflows, the printer helps teams produce in-house, iterate faster, reduce material costs, and streamline logistics in early production stages.

Prototypes

Large-scale prototyping can be produced quickly and cost-efficiently, making more iterations possible without increasing costs. This is useful for innovators and product developers who need rapid design validation in full or near-full scale.

Research and education

Universities and research teams use the BigRep ONE for hands-on training, applied research, and rapid iteration. In-house large-format printing helps students and research groups avoid third-party bottlenecks that slow down experimentation and development.

“I didn’t think I needed 3D printing and now
I can’t live without it.”

Charles Boyce
President of Boyce Technologies Inc.