BigRep’s New One.5X Makes Big Parts Faster & Easier, Plus Introduces Pellet Extrusion
BigRep evolves its one-cubic-meter platform with full XYZ automation and a shift toward high-speed pellet extrusion to slash industrial material costs.
BigRep is pivoting its flagship large-format FDM 3D printer toward a more accessible future. The new One.5X isn’t just 10% faster; it introduces a game-changing pellet extrusion system (later this year) designed to slash material overhead for full-scale industrial parts.
The One.5X has technical upgrades aimed at solving persistent pain points in large-scale printing, such as manual calibration and high material overhead.
Rather than positioning the One.5X as a clean break, Berlin-based BigRep continues to evolve the One platform. The One.5X preserves the defining characteristics of the platform – most notably its one-cubic-meter build volume – while introducing automated XYZ calibration, adaptive mesh bed leveling, pre-configured material profiles, auto-sequential job execution, and Relay Mode, which transfers print operations to a secondary extruder when material depletion occurs.
These capabilities collectively push the platform toward more autonomous operation, enabling extended print cycles – including overnight production – without manual intervention, the company says.
Performance enhancements complement this shift. BigRep says it pairs higher print speeds – up to 250 mm/s – with pressure advance algorithms and vibration compensation, aiming to maintain geometric fidelity and surface quality at elevated throughput.
As for the One.5X’s price, BigRep isn’t saying, but the previous One was in the $40,000 range.
Hardware Refinement, Not Reinvention
The dual extrusion system is now optimized for higher flow rates and broader application flexibility. The system supports nozzle diameters from 0.6 mm to 2.0 mm, throughput up to 200 g/h, and temperatures reaching 280 °C.
Incremental engineering improvements target reliability and material versatility. Dual-drive filament feeding stabilizes extrusion, while diamond nozzles extend component lifespan when processing abrasive materials, the company says. The Switchplate build surface continues to provide modularity across materials, supported by a heated bed reaching 80 °C.
Material handling also receives attention. An optional enclosed storage system mitigates moisture exposure, and integrated sensors enable automatic pause and recovery workflows to prevent print failures.
Software and Workflow Integration
BigRep extends its focus beyond hardware into workflow orchestration. Its software stack integrates print preparation, production planning, and fleet management into a unified environment. Preconfigured material profiles, automated batch tools, and real-time monitoring capabilities aim to reduce setup time while improving repeatability and resource efficiency.
This vertical integration reflects a broader industry trend: large-format systems increasingly compete not only on hardware specifications, but on the coherence of their end-to-end production ecosystems.
Finally Expanding Into Pellet-Based Additive Manufacturing
It’s about time that BigRep evolved to also print with cheaper and more versatile pellet materials. And instead of reinventing the wheel and developing a proprietary pellet extruder, it opted to partner with one of the top extruder makers on the market, U.S.-based Massive Dimension.
BigRep says the jointly developed MDX extruder introduces a simplified architecture with fewer components and reduced weight, facilitating maintenance and improving serviceability. Weighing 25% lighter than its predecessor and built with 40% fewer parts, the MDX minimizes failure points.
Printing with pellets not only lowers material costs and increases deposition rates, but also enables a wider range of materials and additives, which can be particularly relevant for large-scale applications such as molds, furniture, and structural components.
By enabling pellet materials, BigRep can now compete with robotic arm 3D printers as well as FDMs including from JuggerBot 3D, Re3D, and WASP.
BigRep says the MDX should be available by the end of the year but hasn’t said if it will be standard with the One.5X or an optional add on, but we hope to get answers when we see it in person at Rapid + TCT next week.
Taken together, the ONE.5X and the pellet extrusion move underscore BigRep’s strategic direction: sustained iteration on a mature platform, coupled with targeted expansion into adjacent technologies.
BigRep One.5X Tech Specs
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