Berlin gets it right: 3D-printed composite materials

Berlin, August 31, 2026 – What do aircraft fuselages, vehicle roofs, electric vehicles, prosthetics and rotor blades have in common?  Experts could no doubt give a highly detailed answer.  In simple terms, they all rely on composite components whose unique properties make them ideal for a wide range of high-performance applications.  They are comparatively lightweight yet exceptionally strong and rigid and can be engineered to deliver specific mechanical properties. Traditionally, manufacturing these components involves a range of production methods, materials and processes tailored to the requirements of each application.  Depending on the method used, production can be labor-intensive, development cycles can be lengthy and flexibility can be limited.  Berlin startup Endless Industries GmbH is tackling these challenges with integrated manufacturing systems that automate the production of composite components.

Endless Industries was founded as a spin-off from Technische Universität Berlin  by Stephan Knopf, Dr. Mathias Czasny and Dr. Moritz-Ebeling-Rump.  According to the company, the deep-tech startup’s technology is the result of years of research into materials and software.  The founders and their team are working to bring the technology into series production for industries including aerospace, orthopedic technology and defense.  Today, the company employs more than 15 people and is backed by the EXIST Transfer of Research program, Investitionsbank Berlin and Atlantic.  In May, the startup received the Deep Tech Award 2026 from the Berlin Senate Department for Economic Affairs, Energy and Public Enterprises in the Advanced Manufacturing category.

At the heart of Endless Industries’ end-to-end digital manufacturing process are proprietary thermoplastic Endless Fiber materials developed in-house, patented processing heads and the company’s Akio design software. Akio controls the entire manufacturing process,  which consists of three steps.  First, existing machines are equipped with the processing heads and Endless Fiber materials. Next, the software automatically determines the optimal fiber paths based on predefined requirements.  Finally, the machines manufacture the composite components fully automatically according to the calculated fiber layout. To make its Endless Fiber materials easier to integrate into existing industrial production environments, Endless Industries combines them with established engineering plastics.  This preserves the materials’ key properties while allowing the manufacturing process to be defined at the material level.  The patented processing heads are specifically designed to handle pre-impregnated continuous-fiber filaments,  bringing the fiber and matrix together with precision.  Defined pressure and temperature zones and an integrated cutting unit, among other features, ensure consistent processing. Unlike conventional additive manufacturing methods, Endless Industries’ process does not simply build up layers of plastic. Instead, continuous fibers are strategically incorporated into the component itself. The result is an automated, reproducible process for producing lightweight, high-strength composite components while reducing material use, waste and overall resource consumption.

To bring its technology into industrial use, Endless Industries entered into a technology, sales and service partnership in April with BigRep GmbH, which describes itself as a global leader in large-format additive manufacturing. BigRep is also headquartered in Berlin.  Endless Industries provides the continuous-fiber system – including the processing head, materials and software platform – while BigRep supplies the printing hardware with its BigRep IPSO 105 as well as a global sales and service network. The two companies are initially focusing their sales activities on the DACH region, with plans to expand their partner network in the United States, Australia and Asia in 2027 and 2028. The partnership is another development worth watching in Berlin’s technology landscape – particularly as Endless Industries works to establish its technology in the market.