Revolutionizing Manufacturing with Big Area Additive Manufacturing (BAAM): Scaling New Heights of Size, Speed, and Material Diversity

Revolutionizing Manufacturing with Big Area Additive Manufacturing (BAAM): Scaling New Heights of Size, Speed, and Material Diversity


Big Area Additive Manufacturing (BAAM) is a groundbreaking technology that has transformed the landscape of additive manufacturing, offering unparalleled capabilities in producing large-scale structures using thermoplastic polymers and composites. Developed collaboratively by Oak Ridge National Laboratory (ORNL) and Cincinnati Incorporated (CI), BAAM represents a giant leap forward in overcoming the limitations of conventional additive manufacturing systems. With its gantry-based extrusion system, BAAM has the capacity to deposit material at astonishing rates of up to 100 kg/h, enabling the creation of parts several meters in length, width, and height. This article delves into the world of Big Area Additive Manufacturing, exploring its unique features, applications, and the remarkable contributions it makes to industries worldwide.

The Birth of Big Area Additive Manufacturing

BAAM emerged from the need to overcome the constraints of traditional additive manufacturing systems, which were limited in their ability to produce large-scale components efficiently. Conventional 3D printers were often restricted to relatively smaller sizes and slower printing speeds, which hindered the production of large structural parts and hindered their applicability in various industries. Recognizing this limitation, Oak Ridge National Laboratory and Cincinnati Incorporated joined forces to pioneer BAAM, revolutionizing the potential of additive manufacturing in terms of scale, speed, and material diversity.

Unleashing the Power of BAAM Technology

At the heart of BAAM lies its innovative gantry-based extrusion system, which sets it apart from traditional 3D printers. This advanced system allows BAAM to deposit material at an astounding rate of up to 100 kg/h, facilitating rapid and efficient production of large-scale structures. With the capability to create parts spanning several meters in length, width, and height, BAAM opens up exciting possibilities for industries requiring extensive components, such as automotive, aerospace, construction, and renewable energy.

Moreover, BAAM’s material diversity is another compelling feature that propels its applicability to a wide range of industries. The technology can harness various thermoplastic polymers and composites, providing manufacturers with an array of material options to suit their specific requirements. This versatility allows for the creation of parts with diverse properties, such as strength, flexibility, and resistance to environmental factors, catering to the unique demands of each application.

Revolutionizing Manufacturing with Big Area Additive Manufacturing (BAAM): Scaling New Heights of Size, Speed, and Material Diversity

Applications of BAAM: Advancing Industries Worldwide

The versatility and scalability of BAAM have resulted in its widespread adoption across numerous industries. One of the significant applications of BAAM lies in the production of automotive components. By leveraging BAAM’s capabilities, automakers can create large-scale parts with improved efficiency, thereby reducing assembly times and enhancing overall vehicle performance. BAAM’s ability to produce complex geometries also facilitates the creation of customized automotive components, optimizing design and functionality.

The aerospace industry has also embraced BAAM, leveraging its potential to manufacture large structural components for aircraft and spacecraft. With BAAM’s rapid material deposition rates, aerospace engineers can create lightweight and intricate parts that meet stringent performance standards. The efficiency and precision of BAAM make it an indispensable tool in accelerating the development of aerospace technologies.

In the renewable energy sector, BAAM has found its niche in the creation of wind turbine blades. With its capacity to fabricate large-scale structures efficiently, BAAM has revolutionized the production of wind turbine components, driving advancements in renewable energy generation.

Additionally, BAAM’s capabilities extend to the construction industry, where it has been employed to 3D print entire houses. This innovative approach to construction streamlines the building process and offers a more sustainable and cost-effective alternative to traditional construction methods. BAAM’s ability to create large-scale structures in a short period has the potential to revolutionize the architecture and construction industry.

The Future of BAAM: Advancements and Innovations

As BAAM continues to gain traction across industries, the future holds promising advancements and innovations. Researchers and engineers are actively exploring new materials and optimizing the extrusion process to further expand BAAM’s material diversity and enhance the properties of 3D printed components. As the technology matures, BAAM is likely to witness increased adoption in various sectors, including marine, defense, and infrastructure.

Additionally, advancements in BAAM’s capabilities are expected to drive cost efficiencies, making it a more accessible solution for smaller manufacturers and startups. The potential for large-scale, customizable production at a lower cost holds immense promise for manufacturers seeking to stay competitive in the ever-evolving market.


Big Area Additive Manufacturing (BAAM) is a game-changing technology that has redefined the potential of additive manufacturing on a grand scale. By enabling the production of large-scale structures with unprecedented efficiency, BAAM has propelled industries into new realms of size, speed, and material diversity. From automotive components and aerospace parts to renewable energy solutions and architectural marvels, BAAM continues to revolutionize manufacturing across diverse sectors.

As the technology continues to advance and researchers explore new materials and applications, the future of BAAM looks brighter than ever. With the potential to drive cost efficiencies and accelerate innovation, BAAM is poised to reshape industries worldwide, driving progress and ushering in a new era of manufacturing excellence. Embracing the power of BAAM opens the door to endless possibilities, empowering industries to create larger, more intricate, and highly customized components, contributing to a more sustainable and efficient future.

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