Large Format 3D Printing

Suction device made of PET | FFF process | Application: Climate control

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  • 3D printing large components – New possibilities in additive manufacturing

    Hänssler is your partner for the development and production of large plastic 3D printed components. We are at your side throughout the entire process of development, manufacturing and reworking, enabling us to work in a cost-oriented manner.

    3D Printing – What does large format mean?

    We can manufacture your project up to a size of 1 m x 1 m x 1 m with our 3D printers. This possibility sets new standards in many application areas. If your desired component exceeds this size, printing in segments is possible, which can be connected to the desired end product by means of pinning and special bonding.

    Stuhl aus rPETG hergestellt durch großformat 3D-Druck
    Functional chair
    • Material: recycled PETG

    • Process: FFF

    • Printing time: 5 days 8 hours

    • Weight: 12000g

    Application of the 3D printing in oversize

    Large format printing up to 1 cubic meter opens up new avenues in the field of applicable components. A wide variety of ideas can be realized and applied in practice. Numerous materials are available to you at Hänssler for the production of your component. Our filaments are stored in special drying refrigerators to preserve the properties of the materials.

    Fields of application for large-format 3D printing

    3D printed large-format components can be used in many different industries. In addition to mold making, the process also offers many advantages in mechanical engineering. Additively manufactured components are also suitable for applications and fixtures or can be used in transport safety.

    The advantages of the printed mold compared to a milled polyurethane mold

    • Material saving: 3920 g

    • Cost saving: 50 – 75 % compared to previous milled molds

    • Material: recycled PET

    • Properties: higher bending strength and stability

    • Delivery time: only a few days compared to several weeks

    • Printing time: 2 days 18 hours

    Laminating mold for a carbon spoiler I FFF- process I Application: Motorsport

    Series production in the 3D printing process

    Already the prototype is printed on series level. From the very beginning, we aim for process capability and process reliability. We only use manufacturing steps that are repeatable. This starts with determining the correct tolerances and extends to quality assurance.

    Some plastic parts manufactured using 3D printing require rework. A variety of processes are available for this purpose. For example, we can achieve tolerances and significantly improve surfaces using classic manufacturing processes such as turning or milling. For you, this means that you do not have to change suppliers between the prototype phase and series production.

    Sustainability and resource savings thanks to 3D printing

    It is particularly worth emphasizing that the additive manufacturing process benefits the environment. Material is saved during production compared to subtractive manufacturing, as only the required amount of filament is used. As a result, more material can be transported with one delivery than usual and transport costs can be reduced. Valuable resources can be saved as a result. In addition, few to no waste products are produced. Should this nevertheless occur, there are possibilities to recycle the materials or to use already recycled material for printing large components.

    Blumenvase aus rPETG hergestellt durch großformat 3D-Druck
    Sustainable flower vase
    • Material: recycled PETG

    • Process: FFF

    • Printing time: 18 hours

    • Weight: 3100g

    • Diameter: 330mm

    • Height: 830mm

    The right design for 3D printing large components

    It is often only during the development process that it becomes clear how a component can optimally complement the application. After the first component has been created, we have the opportunity to adapt the design in order to optimize the component for the planned application. In this phase, the time factor usually plays a major role. Hänssler can therefore significantly shorten the test phase by optimizing processing and delivery times.

    By adjusting the printing parameters, the 3D printed part can be manufactured with the necessary strength, stability and desired weight. The use of support structures, free-form surfaces, channels, and bionic design allow us to produce large-print parts that are customized and complex. Tolerances can be maintained to within a few tenths of a millimeter through proper design, always depending on the type and size of the component. In addition, there is the possibility of reworking in a wide variety of ways to meet individual customer requirements.

    Quality but also prices and delivery times play a decisive role. It is therefore important to make the right choice already with the semi-finished product. For this reason, we work together with selected and specialized partners. This way we can keep delivery times low even if the material is not directly available in our generous warehouse. We already offer a wide range of materials. They range from standard materials to engineering materials and high-performance materials – including fiber-reinforced ones. Our competence pyramid provides an overview.

    Schedule your 3D printing consultation for large format parts now!

    Our 3D printing experts will be happy to support you in choosing the optimal material and the suitable printing process. Arrange your non-binding consultation appointment now.