Endless Industries and BigRep bring continuous carbon fiber reinforcement to large-format 3D printing
Two-year joint development produces an industrial system capable of printing mechanically reinforced composite parts at production scale
Berlin-based deep-tech company Endless Industries has completed a two-year integration of its continuous fiber reinforcement technology into BigRep‘s large-format additive manufacturing platform, in what the companies have announced as the start of a long-term global technology partnership.
The combined system targets industrial manufacturers seeking high-strength composite parts without the capital costs that are traditionally associated with automated fiber placement (AFP) processes.
From lab to production floor
The technical integration centers on Endless Industries’ continuous fiber print head, materials, and software being incorporated into the BigRep IPSO 105, a high-temperature, large-format industrial printer with a build chamber operating at up to 100°C.
The resulting system produces parts up to a claimed 20 times stronger than unreinforced thermoplastics, while keeping costs below those of conventional AFP systems. Supported materials include PETG, Polyamide (PA), and polypropylene (PP), and fiber architecture is managed through Endless Industries’ proprietary “Akio” software platform. All printed components remain fully recyclable, unlike thermoset-based processes.
Endless Industries, a spin-off of the Technical University of Berlin, developed its continuous fiber system in a vertically integrated manner, covering print heads, materials, and software within a single stack. BigRep contributed industrial hardware, global service infrastructure, and its established partner network, and together the companies have stated that the combination reduces system complexity and supports repeatable, production-grade manufacturing.
“Large-format composite manufacturing has traditionally been craft-based or required multi-million-dollar investments,” said Stephan Knopf, Co-Founder and Chief Executive Officer of Endless Industries. “This partnership removes those constraints. Customers now gain access to a production-ready system for high-strength parts without the traditional barriers to entry.”
“After two years of joint development, we’ve reached a level of technological maturity that will redefine the role of continuous fiber in industrial 3D printing. Now is the right time to bring this innovation to market,” stated Thomas Janics-Jakomini, Chief Executive Officer of BigRep.
Target applications and commercial rollout
The system is pitched at jigs and fixtures replacing metal or CNC-machined tooling, lightweight structural aerospace components, and load-bearing medical devices, including orthoses and prosthetic components. All are applications where strength-to-weight performance and digital manufacturing flexibility are priorities.
Joint sales activities in Europe are set to begin in summer 2026, with initial focus on the DACH region and international expansion across BigRep’s global partner network — covering Europe, the United States, Asia, and Australia — planned for 2027–2028.
