JetX: large-format 3D printing of an exhibition aircraft

The brief and the finished project

The company Expo for you asked us to create a large-format model of the futuristic JetX aircraft as a visual centrepiece for its stand at SiGMA Central Europe 2025 in Rome. The project combined design, creativity and rapid production on a huge scale, with demanding requirements for stability, appearance and transport.

Our first step was to turn the supplied graphic references into accurate three-dimensional geometry. As the finished aircraft was to stand more than 5 metres tall, it had to be divided in CAD software into a series of large segments. Each segment had its own structural design, internal reinforcement and mounting points so that all parts could be safely produced, moved, assembled and given a consistent surface finish on site.

With no usable manufacturing data available, we created a complete bespoke 3D model of the aircraftbased on the available visual references. At this stage, particular attention went into the design of the internal support structure, structural joints, as well as calculations and decisions concerning overall stability.

The exhibit also had to stand at a slight angle without visible supports. This placed considerable demands on a frame that could carry its own weight, allow rapid assembly and be securely anchored to the prepared installation structure.

Production progressed from the large fuselage sections and wings to smaller features and detailed components. After the initial segmentation, we divided the sections into hundreds of smaller partsoptimised for 3D printing. Each was modelled to form the cleanest possible surface after assembly, without visible edges or distracting transitions.

Surface preparation and colour finishing

Once the hundreds of parts had been printed, assembly gradually brought the aircraft into its final form. We carefully aligned, bonded and secured the sections so that the structure would withstand handling and transport. Filling the joints and unifying the surface followed. This was one of the most demanding stages: every transition between parts had to disappear so that the finished surface would read as a single object.

We sanded in several stages, from initial levelling to fine finishing, then applied primer to even out the surface and reveal small imperfections. These were filled and sanded again until the model was ready for colour coats.

The client required the aircraft to follow JetX’s graphic identity faithfully: sharp yellow, deep black and clean white. We used careful masking, multistage painting and thorough coverage of each area. Every colour needed its own coat, curing time and inspection to achieve a consistent, rich and even result.

The colours had to remain bold and uniform across very large surfaces. Through successive coats and checks, we developed the aircraft’s visual character until it appeared as one coherent, professionally finished object.

Installation in Rome

After completion, the model was transported to Italy, where exhibition specialists carried out final assembly and positioning on the SiGMA Central Europe exhibition floor in Rome. Its scale, bright colours, futuristic shapes and clean finish attracted attention, making it the visual focal point of the stand.

The project had a monumental presence on site. Visitors frequently photographed, filmed and shared it, strengthening the client’s overall presentation.

Looking back

The large-format JetX aircraft is one of our largest and most demanding exhibition projects. It brought together creative work, bespoke CAD modelling, rapid large-scale production, surface finishing and preparation for transport and installation. The result demonstrates how modern 3D manufacturing, precise planning and attention to design can create an object that becomes the centrepiece of an exhibition.

For us, it was both a challenge and an opportunity to demonstrate what bespoke large-format 3D production can achieve, and how strongly it can shape an exhibition’s visual identity.