Large 3D Printing Services for Precision Engineering & 3D Fabrication
From full-scale prototypes and development models to tooling, jigs, fixtures and bespoke components, our team reviews the geometry, intended use and wider manufacturing requirements before identifying a suitable production route.
BigRep large-format 3D printer
CAD and design support
Wider in-house engineering services
Large 3D Printing for Controlled Product Development
The process can provide a practical route for full-scale prototypes, production aids, tooling and low-volume parts, particularly where complex geometry, design changes or project quantities make other production methods less suitable.
At Bramley Aerospace, large 3D printing forms part of a wider engineering service. Before production begins, our team can review:
- The 3D model and overall geometry
- Part dimensions and intended application
- Material and environmental requirements
- Critical interfaces and assembly points
- Surface finish and visual requirements
- Tolerances and inspection requirements
- Whether the part should be printed as one piece or divided into sections
- Any machining, fabrication, finishing or assembly needed afterwards
What We Produce with Large 3D Printing
Our large 3D printing service can support development, manufacturing and operational requirements across aerospace, defence and advanced engineering.
Prototypes and development models
- Full-scale prototypes
- Form and fit models
- Design validation parts
- Ergonomic and handling models
- Clearance and installation models
- Functional development components
- Demonstration and presentation models
- Trial parts for assembly planning
Tooling and production support
- Jigs and fixtures
- Assembly aids
- Checking and inspection fixtures
- Drilling and positioning templates
- Patterns and mould tools
- Forming and trimming tools
- Production-line aids
- Protective handling and storage inserts
Bespoke and low volume components
- Housings and enclosures
- Guards and protective covers
- Ducts and channels
- Large brackets and supports
- Replacement and obsolete components
- Bespoke machine parts
- Low-volume production components
- Parts with complex or internally routed geometry
Large-format Additive Manufacturing
BigRep Large-Format 3D Printer
Its enclosed build chamber offers almost one cubic metre of printing capacity, allowing substantial and complex parts to be produced directly from 3D CAD data. Components can be printed as a single piece or divided into planned sections for controlled joining, finishing and assembly.
Before production, our team reviews the geometry, material requirements, critical interfaces and intended application. Printed parts can then move into CNC machining, fabrication, fitting, finishing and assembly as part of a wider 3D fabrication service.
Machine specification
- Machine type: industrial large-format FFF 3D printer
- Year: 2020
- Maximum single-extruder build volume: up to 1,020 × 970 × 985 mm
- Dual-extruder build volume: 945 × 970 × 985 mm
- Extruder configuration: dual extrusion
- Nozzle diameters: 0.6 mm and 1.0 mm
- Standard layer heights: 0.3 mm and 0.6 mm
- Heated build chamber: fully enclosed
- Maximum heated print bed temperature: 80°C
Why Work with Bramley Aerospace?
Our large 3D printing service combines dedicated equipment with practical design support and wider in-house manufacturing, helping customers move from CAD data to finished parts.
Dedicated large-format 3D printing machine
Our dedicated machine supports oversized prototypes, tooling, production aids and bespoke components that exceed standard 3D printing dimensions.
Design and CAD support
Support for large and complex parts
Integrated manufacturing services
Prototype to low volume production
Practical material and production planning
Large 3D Printing for Aerospace, Defence and Advanced Engineering
Aerospace
Large 3D printing can support aircraft development, manufacture and maintenance by producing full-scale models, assembly aids and lightweight production tooling.
Examples: aircraft interior mock-ups, ducts, housings, drill templates, inspection fixtures, protective covers and full-size development parts.
Defence
Defence engineering projects may require bespoke parts and equipment produced around specific vehicles, systems or operational environments.
Examples: equipment housings, maintenance aids, protective enclosures, assembly fixtures, training models and replacement components for established equipment.
Automotive and specialist vehicles
Automotive manufacturers can use large-format additive manufacturing to test designs, prepare production tooling and manufacture bespoke parts for low-volume vehicles.
Examples: body-panel prototypes, dashboards, ducts, trim components, forming tools, assembly jigs and moulds for composite parts.
Advanced manufacturing
Large 3D printing can help manufacturers develop production equipment without investing in conventional tooling for every bespoke or short-run requirement.
Examples: machine guards, robot tooling, checking fixtures, component nests, assembly aids, replacement parts and customised production-line equipment.
Marine engineering
Marine projects often involve substantial curved forms, low production quantities and components shaped around restricted installation spaces.
Examples: moulds, patterns, ducts, consoles, protective housings, deck components and full-scale models used to check installation and access.
Energy and renewables
Energy projects can use a 3D fabrication service to create tooling, prototypes and production aids for large equipment and infrastructure.
Examples: wind-turbine tooling, cable-management components, equipment covers, forming patterns, inspection aids and prototype housings.
Our Large 3D Printing Process
Our process gives customers a clear route from initial enquiry to finished part, with practical checks built in before manufacture begins.
Requirement review
Design and manufacture review
Material and production planning
Printing and post processing
Inspection and completion
From Prototype Development to Repeat Production
Large 3D printing can support early prototypes, design refinement, pre-production trials and repeat low-volume manufacture. Digital models can be updated between builds, helping teams test form, fit, function and assembly before moving into a controlled production route.
Discuss a Large 3D Printing Project
Share your available files, overall dimensions, quantities and intended application with our engineering team. We will review the information and help identify a practical route from digital design to finished part or assembly.
Large 3D Printing FAQs
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