3D-printed exhibition displays for Flender

A gearbox is heavy. It's not exactly easy to place a multi-ton object at an exhibition stand. Our exhibition piece, weighing just under 50 kg, is significantly easier to transport than the original gearbox, which weighs around 1000 kg.

This was precisely the challenge of this project.

For Flender, we had the opportunity to create two of their gearboxes as detailed 3D-printed exhibition models for indoor use. The original weighs about a ton. The goal was therefore to transform a technical heavyweight into an exhibit that could be safely transported, presented with high quality, and practically used in an exhibition environment.

A gearbox is not something you typically just pick up. It's too heavy, too complex, often too valuable, and in its original form, hardly designed for easy presentation at an exhibition stand. In other words: Anyone who has ever tried to move a real gearbox knows that the focus quickly shifts to their back rather than the product.

So we did exactly what we specialize in: making heavy things light – literally.

When the original is too big and too heavy for exhibition construction

Large industrial components are impressive. They stand for precision, performance, and technical expertise. However, in exhibition design and product presentation, they usually also bring significant challenges: high transport costs, complex logistics, difficult handling, and high demands on safety and setup.

Especially with a gearbox weighing approximately one ton, it quickly becomes clear that the original is not the most practical solution for trade fairs, showrooms, or presentations. What's needed then is an exhibition piece that retains the technical impact and detailed accuracy of the original, but is significantly lighter, more manageable, and more versatile in use.

This is precisely where the capabilities of large-format 3D printing from the heart of the Ruhr region become apparent.

A leader in 3D-printed exhibition displays – even when deadlines are tight

These kinds of projects are not exceptions; they are part of our daily work. Our company is one of the leading manufacturers of high-quality exhibition displays. We combine technical expertise, extensive experience in large-format 3D printing, and a machine park of over 30 large-format 3D printers with a build volume of over 1000 x 1000 x 1300 mm, high-quality surface finishing, and a clear understanding of the requirements for exhibition stand construction, marketing, and product presentation, all of which we implement in our in-house paint shop to the highest quality standards.

And even when projects become time-critical, we see it not just as a challenge, but primarily as an incentive. Demanding timelines, in particular, require streamlined processes, flexibility, and high reliability. For us, this is an essential component of professional project work.

Two detailed gearboxes as 3D-printed exhibition models

For Flender, we manufactured two gearboxes as large-format 3D-printed exhibits for indoor use. The aim was not to create simplified display pieces, but rather exhibition models that were as true to the original as possible, with high recognition value and technical significance. Every gear, every shaft, and every contour was based on the original, but in a form that can be moved without a lift platform or heavy-duty logistics.

The finished gearbox exhibit ultimately had dimensions of 655 mm x 460 mm x 255 mm. This resulted in a compact yet impressive 3D-printed exhibition piece that convincingly conveys the design language and technical features of the original.

3D-Printed Exhibition Pieces as a Practical Solution for Industry and Sales

This project clearly demonstrates the added value that large-format 3D printing can offer for exhibition construction and industrial product presentation. When original components are too heavy, too unwieldy, or too valuable for mobile use, 3D-printed exhibition pieces provide a compelling alternative.

They make complex technology visible, understandable, and tangible. They facilitate sales discussions, attract attention at the trade fair booth, and enable products to be presented realistically without incurring the logistical disadvantages of the original.

This is why highly detailed 3D-printed exhibits are a particularly effective solution, especially in industries such as mechanical engineering and technical product presentation.

Material combination for stability, authenticity, and reduced weight

For a 3D-printed gearbox exhibit to not only look good but also appear stable and high-quality in exhibition use, the right material selection is crucial. In this project, different materials were specifically combined to intelligently connect authenticity, stability, and a reduced overall weight.

Among other things, an acrylic glass pane was installed, weighing 9.8 kg, a large steel shaft weighing 21.2 kg, a small steel shaft with a 40 mm diameter and 1.0 kg as well as the 3D-printed gear housing weighing 16.3 kg.

This particular combination highlights what truly matters for high-quality 3D-printed exhibition pieces: stability and realism in critical areas, combined with a significantly lighter overall structure compared to the original. This transformed a multi-ton industrial product into a portable exhibition piece that can be easily carried by two people.

Secure Presentation at the Exhibition Booth

A professional exhibition piece requires not only the component itself but also a secure and clean presentation. Therefore, we also manufactured a display base or holder made of acrylic glass. This ensures the secure positioning of the exhibit at the trade fair booth and simultaneously enhances its high-quality overall impression.

Especially in a trade fair environment, this is a crucial aspect: an exhibit must not only impress but also be stable, easily accessible, and cleanly presented.

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Transport Crate for Secure Shipping and Storage

To ensure optimal protection for the 3D-printed exhibition pieces during shipping and storage, a transport crate made of approximately 18 mm thick OSB panels was also manufactured. It serves for secure transport and protected storage between uses.

Especially for high-quality 3D-printed exhibits, this is an important part of the overall concept. Because only when transport and storage are also considered will the quality be maintained in the long term.

Post-processing and Painting for a High-Quality Surface

A compelling 3D-printed exhibition piece isn't solely created during the printing process. Surface finishing is also crucial for a high-quality appearance and a professional impact at the trade fair booth.

Therefore, the exhibits were meticulously post-processed afterwards. This included sanding, filling, and priming to create an optimal base for the subsequent painting. A high-quality, detailed paint finish was then applied according to customer specifications, tailored for indoor use.

This resulted in 3D-printed gear exhibits that are not only technically impressive but also visually meet the high demands of exhibition construction, showrooms, and professional product presentations.

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