Technical guide
What is LFAM? Large-format additive manufacturing.
How LFAM produces metre-scale parts layer by layer as a single body: the working principle, the parts it suits, the materials involved and the points to consider in design.
What LFAM means
LFAM (Large Format Additive Manufacturing) is an approach in which metre-scale parts are produced layer by layer. The systems described on this site are based on FDM/FFF (material extrusion) technology: thermoplastic material is heated, extruded through a nozzle and deposited layer by layer according to a digital model.
There is no single, universally accepted size threshold for "large format". The term is used for metre-scale parts that exceed the build volume of desktop and cabinet-type systems. The build volume of the BPT 2010 is 2000 × 1000 × 1000 mm.
Why large format?
Producing a large component on a small-volume system requires splitting the part, bonding the sections and finishing the joints. Every joint carries a risk of dimensional deviation, mechanical weakness and additional labour.
Large-format systems remove these joints and allow the part to be produced as a single body. Assembly and post-processing times are reduced, and the part retains the mechanical integrity it was designed for.
Which parts is it suited to?
- Moulds and patterns: casting patterns, thermoforming moulds and master parts.
- Functional prototypes: validating a design at full scale.
- Fixtures and jigs: workholding and inspection aids for assembly and quality lines.
- Low-volume end-use parts: custom and one-off components.
For sector-specific examples, see the Industries page.
Comparison with conventional methods
| Aspect | Conventional methods | LFAM |
|---|---|---|
| Tooling / moulds | Often require a tooling or mould investment | No mould needed; parts are produced directly from digital data |
| Design changes | Require mould or tooling revision | The digital file is updated and a new print is made |
| Geometry | Subject to limits of the manufacturing method | Hollow and complex geometries can be produced |
| Suitable quantity | Unit-cost advantage at high volumes | Economical for single, low and medium quantities |
| Surface | Finished surface depending on the method | Layer lines appear; post-processing applied if required |
| Mechanical behaviour | Generally similar in all directions | May vary with layer direction |
LFAM is not the right method for every part. For high-volume series production, conventional methods are often more economical. The right method is chosen according to quantity, geometry, material and surface requirements.
Materials
LFAM uses thermoplastics. Standard materials such as PLA, ABS, ASA, PA / Nylon and PC offer a wide range of uses. High-performance polymers such as PEEK, PEKK, PPS, PPSU and ULTEM / PEI are preferred for applications with high thermal and mechanical requirements.
Temperature control is critical on large parts. As a part grows, differences in cooling can lead to warping and weak adhesion between layers; a heated bed and a controlled chamber are therefore an important part of large-format systems. On the BPT 2010, the bed can be heated up to 180 °C and the chamber up to 170 °C.
Design considerations
- Print orientation: Layer direction affects mechanical behaviour. On load-bearing parts, the print orientation should be chosen deliberately.
- Support structures: Overhanging regions may need support material. A dual extruder allows model and support material to be printed with separate heads.
- Temperature and warping: Thermal stresses must be considered on parts with large surfaces and thin walls.
- Surface quality: Layer lines appear. If the surface requirement is high, post-processing such as grinding or machining should be planned.
- Dimensional tolerance: The final tolerance depends on the material, geometry and process settings.
How does the BPT 2010 address these requirements?
- Build volume
- 2000 × 1000 × 1000 mm (2 m³)
- Extruder
- Independent dual extruder, 5 kg per head
- Temperature
- Bed 180 °C · chamber up to 170 °C
- Positioning resolution
- 1 µm, closed-loop feedback
- Supply
- 380 V three-phase
Short glossary
- LFAM
- Large Format Additive Manufacturing.
- FDM / FFF
- Two common names for layer-by-layer production by material extrusion (Fused Deposition Modeling, Fused Filament Fabrication).
- Extruder
- The unit that heats the material and feeds it to the nozzle.
- Nozzle
- The tip from which the molten material emerges.
- Anisotropy
- Variation of mechanical properties with direction.
- Support material
- Material printed to hold up overhanging regions and removed afterwards.
- Chamber
- The enclosed, temperature-controlled space around the build area.
Is your part suited to LFAM?
Share your 3D file and technical requirements. We will assess the production approach together and, if you wish, print a sample.