Zend Technologies is one of the largest and most popular companies producing a wide variety of tools and frameworks for PHP. Their community forums rely on phpBB.
Inspired by Max Berry's book, Jennifer Government, NationStates is one of the most popular online simulation games. The forum boasts over 5 million posts and 200,000 users.
As the official board for the world-famous band Queen, this community hosts a wide variety of discussions by Queen fans from around the globe.
OpenOffice.org offers a free and fully-featured office suite which meets the needs of the common consumer all the way up to large enterprises.
The VideoLAN project produces the extremely popular VLC media player software. Their forums provide support for users of the software as well as the development community.
Hugely popular Mozilla community providing support for Firefox, Thunderbird, Seamonkey and other well known Mozilla products. Over 350k members and 4 Million posts.