Endless Industries and BigRep bring continuous carbon fiber reinforcement to large-format 3D printing

Endless Industries, a Berlin-based spin-off of the Technical University of Berlin, has completed a two-year joint development with BigRep to integrate its continuous fiber reinforcement technology into BigRep's IPSO 105 large-format industrial printer. The combined system, which includes Endless' proprietary print head, materials, and Akio software, produces parts up to 20 times stronger than unreinforced thermoplastics while keeping costs below those of automated fiber placement (AFP) systems. Supported thermoplastics include PETG, PA, and PP, and all printed parts remain fully recyclable. Joint sales in Europe begin summer 2026, with global expansion through BigRep's partner network planned for 2027–2028.

This partnership addresses a persistent gap in industrial additive manufacturing: the ability to produce large, mechanically reinforced composite parts without the multi-million-dollar capital investment of AFP or thermoset-based processes. The integration of continuous fiber into a large-format FFF platform at a 100°C build chamber temperature targets applications in jigs and fixtures, lightweight aerospace structures, and load-bearing medical devices such as orthoses and prosthetics. The move places Endless and BigRep in direct competition with systems from Markforged (for smaller continuous fiber parts) and with AFP specialists like Electroimpact and Coriolis Composites, but at a significantly lower price point. The vertical integration of print head, materials, and software reduces system complexity and qualification risk for industrial buyers.

For industrial manufacturers evaluating composite AM, the key question is whether Endless and BigRep can deliver the repeatability and material certification that aerospace and medical customers require. The two-year joint development suggests technical maturity, but the real test will be in production-floor reliability and the ability to support a global service network. Buyers should expect to see initial reference parts from the DACH region before committing to broader deployment.