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Go Big!

The Biggest Things You Can 3D Print

by All3DP
Updated Aug 22, 2024

From life-size dinosaurs and boats to rockets and houses, there’s no size
limit to what you can 3D print. Learn how.

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JUMP TO SKIP

Displays, Props & Signage Design Tips & Software for Large-Scale Printing
Furniture, Boats & Bikes The Largest Large-Format 3D Printers
Houses, Bridges & Architectural Elements Comments
Industrial & Metal Parts

L
arge-scale 3D printing spans several technologies, multitudes of materials, and
a vast array of applications. What defines large is open to interpretation, but
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certainly, houses, boats, and life-size furniture qualify. These examples and many
more are entering the mainstream as manufacturers, artists, and businesses turn to
3D printing for their large-scale product needs, whether it’s buying a large-scale 3D
printer or turning to a 3D printing service.

Every year 3D printers get larger as machine makers push the boundaries of
technology with new printers to print more and print bigger.

Craftcloud by All3DP
Get large parts 3D printed professionally at a low cost!

3D printing service WhiteClouds 3D printed giant product replica statues of Funko Pop! toys for the Deadpool and
Wolverine movie premier (Source: WhiteClouds)

Size is technology- and material-dependent, and there are trade-offs (usually detail)
with size, which makes selecting the right 3D printer a critical component of
success. The software also plays a role in creating large objects since often, the best
way to print large is to print in pieces and assemble.

Let’s take a look at what it means to print large through the lens of specific things
you may want to print:

• Displays, Props, & Signage


• Furniture, Boats & Vehicles

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• Houses, Bridges & Architectural Elements

• Industrial & Metal Parts

In each section, we feature examples of large-scale parts and how they were made,
by whom, often with the brand of 3D printer used.

But if you want to order your large 3D printed part instead of printing it yourself, there
are a growing number of companies that specialize in this area.
3D PRINTING LARGE OBJECTS – QUICK
START GUIDE

Displays, Props & Signage

The Dutch Naturalis Biodiversity Center has its own 3D printing lab and produced this replica of its T-Rex using two Builder Extreme
1500 Pro 3D printers (Source: Naturalis)

Museum curators, movie set and prop designers, amusement parks, convention and
expo display makers, and countless others are turning to large-format 3D printers for
faster and more affordable production of large objects. Besides the speed and cost
advantages, no sculptural or artistic talent is required outside of creating the digital
model in computer-aided design (CAD) software. Plus, there’s a vast array of
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possible materials, from ultra-lightweight foam to extremely durable carbon-fiber-


filled nylon.

One great example is the life-size T-Rex shown above from the Fukui Prefectural
Dinosaur Museum in Fukui, Japan. The museum couldn’t buy a T-Rex or dig one up,
so it turned to the next best thing, 3D printing. Based on 3D scans from actual T-Rex
fossils, it commissioned a 12-meter-long and 5-meter-tall life-size replica printed in
large parts using two large-scale 3D printers from the company Builder Extreme. The
T-Rex was printed in PLA plastic filament.

Artists apply a plaster covering to the 17-foot tall 3D printed replica of Michelangelo’s David reconstructed for
Expo 2020 Dubai (Source: Italy Expo 2020)

Another example is this 17-foot, 3D printed twin of Michelangelo’s David (above) that
went on display at the Dubai Expo 2020 to promote tourism in Florence. A polymer
3D printer large enough to produce the replica in one piece at super fine detail was
impossible, so it was divided into 14 printable pieces and then assembled by hand.
The marble appearance came from a hand-painted layer of plaster containing marble
dust.

Inside 3D printed David is a lattice structure that helped keep its weight to just 550
kg or about 11% of the original marble David, yet it was strong enough to pack and
ship.

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Styles Werbetechnik in Germany uses Tractus3D large-scale FDM printers to produce lighted signage letters
faster than traditional methods (Source: Tractus)

German sign-making company Styles Werbetechnik had several reasons to turn to


large-scale 3D printing for outdoor signage and channel lettering. The company
wanted not only to speed up production but take letter-making in-house and stop
relying on standard letter designs from overseas producers. The company turned to
polymer FDM printing, which provided limitless design possibilities for
manufacturing profile letters, the company says. For example, the depth of letters
used for lighted signage was limited to a 60 mm minimum with traditional methods
but reduced to a 30 mm depth with 3D printing. Since the 3D printers don’t need to
be watched during the process, they can also run at night and on the weekends,
accelerating production time.

The Smithsonian Museum 3D printed 120 life-sized statues of female leaders from the fields of STEM (Source:
IF:THEN)
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Last spring, the Smithsonian Institute in Washington, D.C., installed an exhibit


honoring women scientists (above) that included 120 life-size 3D printed statues of
their likenesses. Called “IfThenSheCan – The Exhibit”, it was the largest collection of
statues of women ever assembled at a single location at one time. Each statue was
printed using FDM technology.

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Furniture, Boats & Bikes


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The Bounce chair designed by Philippe Bietenholz and 3D printed by manufacturer Mates (Source: Mates)

Interior designers are turning to large-format 3D printing to realize their visions of


intricate design and unique materials. Polymers, especially recycled plastics, are the
most used materials for 3D printed furniture and chairs are the focal point.

At the 2024 Berlin Design week, young designer Philippe Bietenholz displayed his
simple, yet innovative 3D printed chair (pictured above). Constructed in one piece in
recycled polypropylene infused with glass fiber by a robot-arm 3D printer at
manufacturer Mates, this Bounce chair can easily be recycled again.

This child-size school desk in Gambia (below) is an example of 3D printing solving a


practical need. Lightweight and durable, this design can be produced in recycled
plastic, also solving the plastic waste problem. This model was printed in PETG
plastic commonly used for beverage bottles, on the Magnum 3D printer from The
Industry Sweden.

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A prototype desk testing the concept of 3D printing school furniture in Gambia, possibly using recycled plastic
(Source: The Industry Sweden)

There are countless examples of beautiful 3D printed chairs and tables, but some of
the most recent examples include the lovely soft yarn look of the Woven Loopy Chair
designed by Gareth Neal (below left) and 3D printed with a robotic arm 3D printer by
the New Raw. There also the Steam lounge chair designed by Slicelab and 3D printed
with PETG pellets on the EXT 1270 Titan Pellet 3D printer from 3D Systems (below
center) and a chair 3D printed with 50% recycled wood by designer Türkiye Simge
Goorany.

As robotic arms fitted with material extrusion systems become more accessible, one result has been 3D printed
furniture, like these chairs (Source: New Raw, 3D Systems, Circula)

Entered into the Guinness Book of World Records as the largest solid 3D printed item
to date, is the specimen below (left), the 3Diringo, measuring 7.72 meters long.
Printed by the University of Maine Advanced Structures and Composites Center in
2019 on its MasterPrint 3D printer, the boat is made of plastic and wood cellulose,
was 3D printed in just 72 hours, weighs 2.2 tons, and yes, it does float. In April, the
University of Maine unveiled its newest large-format 3D printer, even bigger than its

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first. The new Factory of the Future (FoF 1.0) FoF 1.0 can print objects up to 96 feet
long, 32 feet wide, and 18 feet tall (29 x 9.8 x 5.5 meters) and with a remarkable
output rate of 500 pounds (227 kilos) per hour. Perhaps, and even bigger boat is
planned.

Entirely 3D printed real-sized boats. Left is the 3Dirigo produced by the University of Maine, and right, the Abu
Dhabi water taxi by Al Seer Marine.

Also in the Guinness Book of World Records as the largest 3D printed boat is the 3D
printed water taxi (above, right) manufactured by Al Seer Marine and Abu Dhabi
Maritime. Crafted out of recycled polymer with a custom-built robotic arm 3D printer
by CEAD, Al Seer Marine plans to manufacture dozens of these boats for the Abu
Dhabi region to be introduced later this year. The 12-meter-long and 3.6-meter-wide
water taxi will hold 29 passengers with spaces for bicycles and wheelchairs.

3D printed steel-frame e-bike from Urwahn (Source: Urwahn)

Bicycle makers have tuned to 3D printing in the past several years to solve the
biggest problem in their manufacturing chain, welding. 3D printing frames as single

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pieces not only saves time but enables new design freedom that isn’t limited by
structural joints. Bike makers have produced models in titanium, steel, and carbon-
fiber composites.

The steel-framed e-bike below from Urwahn is mass-produced using metal 3D


printing to create a balance of form, function, lightweight construction, and material.
The special rear end suspends the rear wheel elastically and generates a new kind of
riding comfort, the company says, while the steel frame integrates the motor and
battery.

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3D PRINTING LARGE OBJECTS – QUICK


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Houses, Bridges & Architectural Elements

3D printed sustainable House Zero from Icon (Source: Icon)

The largest 3D printing projects are buildings and houses, and they’re getting larger
every year. The two-story barrier was broken just a few years ago, and now the aim is
to reach even higher.

Although few buildings are just 3D printed and often require or combine structural
supports, such as rebar reinforcement or traditional timber-frame construction, the
technology is finding its way into projects from homes to hotels because of its
speed, labor savings, and durable construction. The global construction 3D printing
market (something that didn’t exist not long ago) is projected to grow nearly 20% in
the next five years.

The two-story building below by architectural design and engineering firms Hannah
and Cive with Peri 3D Construction behind the 3D printer, showcases the engineering
feat of construction 3D printing. The 4,000-square-foot home has already been sold
to an anonymous bidder and will take a total of two years to complete. Peri’s Cobod

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Bod2 gantry printer, a household name in the 3D printing construction world, is used
to extrude the specialized concrete mix into stairwells and other functional
structures in a total of 330 active printing hours.

The US’s first fully 3D printed two-story house is located Houston (Source: Hannah)

A Rising Trend
Top Companies Building 3D Printed Houses

In addition to the construction of buildings, 3D printers are widely used for


architectural elements, including façades and historical accents for restorations, as
well as interiors, including walls, displays, and room dividers. There are even 3D
printed floors, 3D printed bridges, and 3D printed artificial coral reefs.

Concrete-like materials aren’t the only option in architecture, polymers also play a
role. Specializing in large-scale 3D printing with robotic arm polymer extrusion
machines, Branch Technology creates everything from sculpture to space habitats.
Its innovative architectural panel system called BranchClad opens up new
opportunities in building façades. Just take a look at the lunar surface installed on
the side of the US Space and Rocket Center’s new Space Camp Operations (below).
Created using a lunar digital scan, these facades show amazing fidelity to the

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moon’s surface. The positive mold of the lunar pattern is 3D printed and then coated
with a stucco material.

Branch Technology’s new 3D printed moon wall installed on the side of the US Space and Rocket Center’s new
Space Camp Operations (Source: Branch Technology)

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Industrial & Metal Parts

The Stargate metal 3D printers at Relativity Space (Source: Relativity Space)

Rocket maker Relativity Space claims that its 3D printed rocket, the Terran 1, was the
largest single 3D printed structure ever made, and they may be right. Before its
recent launch and ocean “landing”, it stood 35.2-meters tall and had a 2.3-meter
diameter. The company’s next rocket Terran R is just as big. Both were 3D printed in
a proprietary metal with the company’s Stargate 3D printers, which use robotic arm
wire directed energy deposition technology.

The rocket’s ability to withstand the pressures of the launch was a big win, the
company said, proving the structural integrity of its metal 3D printing method.

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Queen Maxima of the Netherlands officially opened the MX3D metal 3D printed bridge. Photo by Adriaande Groot
(Source: MX3D)

The metal bridge (above) spanning a canal in Amsterdam designed by Joris


Laarman Lab was printed by MX3D using robotic arm wire arc additive
manufacturing technology. The 12-meter long, stainless steel “smart bridge”
includes an embedded sensor network that helped Amsterdam researchers study
the role of IoT systems in the built environment. The structure was developed with
generative design and topology optimization techniques to enable its stunning
design while making it lighter. It was, however, not intended to be permanent and
was removed last autumn after its two-year permit ended.

The beauty of the MX3D bridge highlights the use of metal 3D printing for art and
sculpture. Below is another MX3D-printed creation by artists Mariagrazia Abbaldo &
Paolo Albertelli installed in Torino, Italy’s Royal Gardens. Called “The Whale Pass,”
the 880-kilo sculpture shows the fins of passing whales emerging from the ground
as if they were the open seas. The artists chose metal 3D printing for the final work
in part because it follows their design process. All the models made during the
project were 3D printed.

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“The Whale Pass” designed by Mariagrazia Abbaldo & Paolo Albertelli and 3D printed by MX3D (Source: Studio
C&C)

Looking at large-scale metal 3d prints for industrial use, companies in the marine, oil
& gas, and heavy construction equipment industries are able to produce large parts
much faster and often on-site. For example, the marine propeller below 3D printed
using WAAM technology to produce a near-net shape that is then machined to
tighter tolerances. WAAM, in this instance, replaces forging and can be done closer
to the point of need using less raw material.

This marine propeller was one of the first examples of the industrial application of WAAM technology (Source:
RamLab)

3D printing metal also enables parts to be lighter weight since 3D printing can
produce shapes not possible with forging or casting. The airplane landing gear
component (below), at 455 x 295 x 805 mm, is the world’s first laser powder bed

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fusion 3D printed part of its size, according to printer manufacturer SLM Solutions.
Not only is the component 15% lighter than a traditionally forged component, the
technology also slashed the turnaround time.

Since the component is a part of the system that transfers loads from the wheel to
the plane’s structure, it was manufactured out of titanium for strength. The choice of
material gives the part strong mechanical properties while being corrosion-resistant
without coatings. It was printed using the quad-laser SLM 800 3D printer.

“Additive manufacturing contributes to saving time in the qualification and


certification phases by rapidly providing the parts for testing. We were able to
produce the main fitting in a few days vs. a few months with the forging process,”
says Gerhard Bierleutgeb, EVP of global services and solutions at SLM Solutions.

3D printed nose landing gear part for private jets (Source: SLM)

3D printing large molds for casting metal parts is another application of 3D printing
that favors size. For metal industrial parts that must be cast, the mold-making step
is labor-intensive and time-consuming. With sand 3D printers, manufacturers can
directly 3D print sand casts and molds without ever needing a full-size model. The
VX4000 from Voxlejet (below) is the world’s largest sand mold 3D printer using
binder jet technology to turn out not only huge molds but potentially thousands of
molds in one print session.

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The VX4000 sand 3Df printer from Voxlejet (Source: Voxeljet)

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3D PRINTING LARGE OBJECTS – QUICK


START GUIDE

Design Tips & Software for Large-Scale


Printing

Scout a 30-foot tall 3D printed statue by White Clouds assembled from 365 individual 3D printed parts that each took 28 hours to
print on 55 3D printers (Source: White Clouds)

If you want large items, 3D printing in one piece is often ideal since it eliminates
assembly labor, speeds up production, and can increase structural integrity because
there are no joints or seems. In the next section, we list the largest 3D printers
available in a wide range of technologies.

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But large printers aren’t your only option. When your object is just too large for even
the largest machine, you’ll can segment it into pieces. Let’s take a look at the best
way to accomplish printing in puzzle pieces to ensure a perfect fit.

Jason Kongchouy and his Perth, Australia-based model-making team CDM-Studio used a BigRep large-format
printer but still had to segment their model shark (Source: CDM-Studio)

How to Split a Model into 3D Printable Pieces


To accomplish large-scale 3D prints, you can segment your model directly in your
CAD software, such as Fusion or Solid Works, which has the advantage of letting you
design some assembly and alignment aids, such as pegs, bump and groves, lips, or
hole and slots.

If you simply plan to glue your large object together or use screws (which are only
applicable with more robust materials such as carbon-fiber-filled nylon) you can
leave the segmenting to your slicer tool, such as Cura. With Cura’s Mesh Tools the
segmentation is quick and automated.

When segmenting your digital model manually, avoid cuts that go directly through
detailed areas and split your model to require the least amount of support. You may
want to avoid splitting at the weakest points in a design, namely those areas that are
much thinner than the rest of the model.

For more on manual model splitting, check out our full guide linked below.

Big Dreams, Small Printer


How to Split an STL File / 3D Model for 3D Printing

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The Largest Large-Format 3D Printers

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Gefertec Arc60x WAAM metal 3D printer (Source: Gefertec)

If you’re shopping for a large-format 3D printer, there are many to choose from. If you
aim to create plastic parts, such as displays, props, and signage, there are large-
format filament 3D printers that are essentially giant versions of the desktop
filament printers you may already be familiar with. Some are capable of printing with
engineering-grade durable materials.

In the guide linked below, which we keep updated with the most current products,
you’ll find the top 12 names in large-format plastic filament printers.

Think Big. Print Big.


Best Large-Format 3D Printers for Professional Use

If you want to go larger than the largest filament printer (+1,600 x 1,200 x 1,300),
you’ll need a robotic arm 3D printer. These are just like they sound; a robotic arm
with an extruder head mounted on the end. They can be placed on a track or an
overhead gantry, so they, theoretically, can print to the size of the available track.

Another advantage of robotic arm printers is that they typically print with polymers in
a more economical pellet format. If you’re looking for a robotic arm 3D printer, we’ve
got you covered with our guide to the best; just follow the link below.

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3D Printing at Arm's Length


Robotic Arm 3D Printing – The Ultimate Guide

Resin 3D printing generally isn’t available larger than 1,000 mm except for a few rare
exceptions, such as the Kings 1700 Pro and the 3D Systems ProX 950, because of
the extremely long print times. Resin generally takes far longer than any material
extruded through a nozzle.

Mid-size concrete 3D printers excel at large-format artistic applications (Source: Concrenetics / Vertico /
Incremental3D)

Concrete 3D printers are a surging market not only for home construction but for any
type of concrete form, furniture, architecture, and even planters and sculpture. At the
end of our guide to concrete 3D printing, you’ll find the latest offering of concrete 3D
printers.

3D printing very large metal parts is typically achieved with one of the directed
energy deposition 3D printing technologies, such as wire arc additive manufacturing
(WAAM). These methods use 3D printing heads mounted on robotic arms with a
broad reach and are only limited by the arm size. The largest metal printer, thought to
be the Relativity Space Stargate, is a wire directed energy deposition 3D printer on a
robotic arm. Stargate is not for sale but for a guide to WAAM machines that are,
follow the guide linked below.

Massive Metal Prints


WAAM! What Is Wire Arc Additive Manufacturing?

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3D Printing Technology Largest Known Maximum Print


(commercially available) Size (mm)
Printer

Gantry Extrusion CEAD BEAD 50,000 x 11,000 x


5,000

Laser & Wire Directed Energy ADDere System III 40,000 x 8,000 x
Deposition (DED) 2,000

Robotic Arm Extrusion CEAD Flexbot 40,000 x 4,000 x


3,000

Gantry Construction 3D printing COBOD BOD2 Modular 34,300 x 14,600 x


8,500

Cold Spray Titomic TKF 9000 9,000 x 3,000 x


1,500

Binder Jetting Voxeljet VX4000 4,000 x 2,000 x


1,000

Vat polymerization ProtoFab Duch Group 2,400 x 800 x 800


SLA2400*

Wire Arc Additive WAAM3D RoboWAAM 2,000 x 2,000 x


Manufacturing 2,000

Fused Deposition Modeling 3ntr Sequoia 1,200 x 1,100 x


(FDM) with Filament (heated 900
chamber)

Fused Deposition Modeling Modix Everest 970 x 1,030 x


(FDM) with Filament (no heated 2,000
chamber)

Metal Laser Powder Bed Fusion E-Plus EP-M1250 1,258 x 1,258 x


(LPBF) 1,350

Polymer Selective Laser Farsoon Flight HT1001P 1,000 x 500 x 450


Sintering (SLS)

*currently only available in China.


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Lead Image: The giant Factory of the Future (FoF 1.0) 3D printer was unveiled at the
University of Maine in April 2024. It can print a single object roughly the size of an
adult blue whale.

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