Endless ONE Continuous Fiber 3D Printer’s Open Material Compatibility Enables Customized Manufacturing

Berlin-based Endless Industries’ Endless ONE is a medium-scale continuous fiber 3D printer designed to deliver strength, scalability and customization across industries, from medical to automotive and aerospace. The Endless ONE prints with continuous carbon fiber to provide superior strength and lightweight properties, making it well suited for demanding structural applications.

Unlike traditional 3D printing, which relies on polymer or metal powders, continuous fiber technology gives parts exceptional mechanical durability, which is crucial for robust and lightweight designs. The printer’s medium build volume (600 mm × 400 mm × 440 mm) and open material compatibility make it adaptable for diverse needs, enabling customized manufacturing across varied industrial applications.

The company manufactures the continuous filaments in-house, with the special fiber filaments enabling users to print parts with high strength and low weight. This enables users to save time and money when printing large-scale jigs, fixture and tools for production needs. The open system also enables users to choose the right material that works for a particular application and possibly open up new applications. The continuous fiber core is filled with long continuous fibers for a great strength to weight ratio, compared to unfilled filaments.

Orthotic Production for Orthopedic Technicians

Orthotic parts typically require strength and a lightweight structure, which can be challenging to achieve with conventional manufacturing due to carbon fiber’s cost and complexity. With the Endless ONE, orthopedic technicians can 3D print customized, durable and lightweight orthoses tailored to patient specifications. This innovation not only reduces production time and cost but also enables an unmatched level of individualization.

Tooling for Composite Part Production

Traditionally, molds for composite part production are made from metal or composite materials to withstand autoclave conditions. With the Endless ONE’s continuous fiber technology, manufacturers can now create 3D printed tooling that endures high autoclave temperatures and pressures at a fraction of the cost and production time of conventional tooling methods.

“As we unveil the Endless ONE, we’re excited to showcase the revolutionary potential of continuous fiber 3D printing,” says Stephan Körber, Endless Industries CEO. “This launch is a key step in our mission to make advanced, large-scale 3D printing more accessible across industries.”