ONE

The ONE is an FDM 3D printer from BigRep with a 1005 x 1005 x 1005 mm build volume.

Specifications

Large-scale industrial 3D printing requires specially designed machines that can manage the physical weight of completed parts and handle the massive volumetric flow of extruded material. The German manufacturer BigRep established itself as a pioneer in this segment with the BigRep ONE (including its widely adopted v3 and v4 revisions). This printer is built for the direct production of full-scale prototypes, sand casting molds, furniture, and large structural components for the automotive and aerospace sectors. Its heavy, open-frame design allows operators easy access to the build area from all sides, which is critical when handling objects that can weigh up to 100 kg.

Calibration

Operating a large-format industrial machine like the BigRep ONE requires systematic calibration to maintain geometric accuracy across large distances. Follow these 8 calibration steps:

• Chassis Leveling and Squaring

Before performing any calibration, the printer must be physically leveled relative to the shop floor using its adjustable heavy-duty industrial leveling feet. The frame must have zero twist.

Common defects

• Hardware defects and mechanical weaknesses
• Warping on Large Prints due to Open Chamber: Slicing large-format objects in ABS or ASA often fails due to the open-frame design. Drafts cause the prints to warp, lift at the corners, and split along layer lines.
• Solution: Restrict printing to PLA, PETG, and TPU. If ASA is necessary, use low-shrinkage formulations and set up windbreak panels around the machine.

What it is used for

Best applications:

• Sand Casting Molds and Plugs: Rapid production of large-scale foundry tooling in PLA.
• Furniture and Art Installations: Direct printing of full-scale chairs, tables, and architectural panels.
• Automotive Exterior Prototyping: Printing full-size bumpers, dashboards, and aerodynamic mockups.

Poor applications:.