When it comes to revolutionizing transportation, BigRep's large-format 3D printers are leading the charge. From solar-powered race cars competing in the Australian outback to serially-produced underwater scooters and customizable electric vehicles in China, BigRep's industrial additive manufacturing systems are breaking down barriers that have traditionally limited innovation in the automotive and mobility sectors.

Breaking Barriers in Solar Vehicle Development

The race toward sustainable transportation extends beyond electric vehicles powered by grid electricity, which still largely comes from fossil fuels. Solar-powered vehicles represent the next frontier in truly sustainable mobility, offering energy independence and a genuinely reduced carbon footprint.

Research teams participating in events like Australia's Bridgestone World Solar Challenge are pushing the boundaries of what's possible with integrated solar power. However, these small volunteer teams face a significant challenge: access to expensive traditional manufacturing technologies. This is where BigRep's large-format 3D printers become game-changers.

Heat-Resistant Solutions for Solar Racing

Futuro Solare, an Italian-Sicilian team of volunteer engineers, exemplifies how BigRep 3D printing enables solar vehicle innovation. When developing their Archimede 1 solar race car, they needed custom battery fixtures that could withstand heat, remain lightweight, and be easily updated as their prototype evolved. Traditional custom milling was prohibitively expensive, especially given the likelihood of needing multiple iterations.

The parts were printed using high-temperature resistant filaments, offering the temperature resistance, strength, and printability needed for this demanding application. The fixtures were installed in their current solar-car and have since been quickly and easily updated to fit with their ever-evolving design. This flexibility is crucial for research vehicles that constantly evolve as teams learn and improve.

Precision Testing Through Scaled Models

Team Sonnenwagen from Germany's Aachen University faced a different challenge: their full-sized solar race car was too large for the university's wind tunnel. Wind tunnel testing is critical for understanding aerodynamics, validating downforce and lift, and ensuring driver safety at speeds reaching 140 km/h through the Australian outback.

BigRep sponsored Team Sonnenwagen and provided the solution: a perfectly scaled 1:2.5 model of their vehicle. With the massive one-cubic-meter build volume of BigRep's industrial 3D printers, they produced a model that could fit in Aachen University's wind tunnel. Because of the model, they were able to validate the vehicle's downforce and lift, confirm its sail characteristics, and conduct aerodynamic tests that helped the team compete and stay safe.

This application showcases one of BigRep's key advantages: the ability to produce large-scale models and prototypes that simply cannot be created on smaller desktop 3D printers.

Customization: The Future of Electric Vehicle Manufacturing

Electric vehicle manufacturer XEV is using BigRep 3D printing to revolutionize how production cars are made and sold. As the first company in China to implement the BigRep PRO into their manufacturing process, XEV has virtually eliminated traditional molds and tooling, creating a flexible and efficient production system.

By implementing additive manufacturing with the BigRep PRO, XEV has virtually eliminated the need for limited and resource-intensive tooling. 3D printing has allowed for fewer components, faster technical updates, and significantly reduced production cycles. It also dramatically reduces production costs, meaning the savings can be passed on to customers.

The company offers two layers of customization: surface design customization (allowing customers to express individual identity or corporate values) and modular functionality (developing adaptable upper body modules to fit various customer needs). Thanks to standardized fixing methods between 3D printed customized parts and the car body, modifications can be made with significantly less engineering work than traditional methods.

"The PRO gives us better geometric precision thanks to its reliable machine design. Then its versatility provides us more opportunities to try different material and processes. With the PRO, it's much faster for us to develop more customization possibilities and applications," said Jiawei Wu, Additive Manufacturing Director at XEV.

Serial Production with the BigRep ONE

The AMAZEA underwater scooter represents another milestone: the first consumer water sports mobility device to be 75% additively manufactured. Developed by German-based JAMADE, this innovative product demonstrates how BigRep 3D printing has progressed beyond prototyping into serial production of consumer end products.

"We opted for the BigRep ONE due to its cost efficiency, accuracy and quality when compared to the extremely high investment for traditional tools, particularly in the first year's lower quantity," the JAMADE founders explained.

The BigRep ONE's 1m³ print volume allowed production of the scooter's body and front parts as single pieces, eliminating leak risks from assembled smaller parts. This ability to print large components as single pieces is a critical advantage that only large-format systems like the BigRep ONE can provide.

The AMAZEA scooter offers impressive specifications: maximum speed of 20 km/h underwater or 30 km/h gliding above water, operational depth up to 18 meters, and just 25 kg weight (without battery). The emission-free and low-noise design allows exploration of marine life without disrupting the ecosystem.

"This scooter is a BigRep showcase of our digital solutions empowering production by leveraging the full potential of large-format 3D printers," says BigRep Managing Director Martin Back. "It also signifies the rapid progress of 3D printing into the serial production of consumer end products, opening a new dimension for AM in similar niche but high-tech markets as well."

The Road Ahead

From volunteer research teams pushing solar technology forward to manufacturers reimagining vehicle production and customization, BigRep's large-format 3D printing technology is fundamentally changing transportation. These real-world applications show what's possible when innovation meets the right manufacturing technology.

The benefits of large-format additive manufacturing are clear:

  1. Democratized Innovation: Small teams and startups can compete with established manufacturers
  2. Rapid Prototyping: Faster iteration cycles accelerate research and development
  3. Sustainable Production: Local manufacturing reduces shipping and environmental impact
  4. True Customization: Individual customer needs can be met economically
  5. Efficient Production: On-demand parts and flexible manufacturing simplify development

Because of the opportunities afforded by BigRep's large-format additive manufacturing systems, innovative researchers like Futuro Solare and Team Sonnenwagen have access to resources never previously accessible at their scale. Accelerated research into integrated renewable power has been possible, inching the world closer to reliable solar-powered vehicles for new heights of environmental responsibility and energy independence.

As large-format 3D printing technology continues to advance, we're moving closer to a future where sustainable, customized, and accessible transportation is available to everyone. Whether it's solar-powered vehicles for energy independence, customizable electric cars that reflect individual identity, or serially-produced consumer products like the AMAZEA scooter, BigRep's additive manufacturing is driving us toward a more sustainable and personalized future of mobility.

At MatterHackers, we're excited to be part of this manufacturing revolution. The transportation revolution isn't just about what powers our vehicles. It's about how we make them, who can make them, and how quickly we can adapt them to serve real human needs. BigRep's industrial 3D printing technology is proving to be the key that unlocks all of these possibilities.

Interested in learning more about how BigRep's large-format 3D printing can transform your manufacturing process? The MatterHackers team is here to help you explore BigRep's lineup of industrial additive manufacturing systems and find the right solution for your application.