At the start of 2025 I printed a giant tuxedo and top hat wielding cow for my long-time client. We already had the base 3D model made last year, but we had to print at the largest possible size my 3D printer (Prusa MK4) could possibly do. Exploiting the large size's new opportunities, I added a flowy, leopard-print design to the suit and hat.
Printing at such a large scale imposes some challenges. First of all, clearances had to be adjusted (0.2mm clearance at regular scale might translate to 1mm when super-sized). Secondly, the size and weight mean a huge amount of material is required, and printing mistakes and failures cost way more time and money. In total, the cow weighed approximately 3kg (over 6lbs), which translates to around 80EUR in 3D printing material alone. Thirdly, things just don't print the same at such a scale. FDM prints such as this one need adequate cooling time between layers and mindful design and slicing to prevent warping or blown out layer lines. With my extensive previous experience, navigating these difficulties wasn't too hard, and we produced a giant cow around 36cm (~14").
