UK-built large-format hybrid 3-D printer to be unveiled

Martin Jewell, CTO of Rapid Fusion, putting Medusa through its final testing

The first UK-built large-format hybrid 3-D printer is due to be unveiled later this month in what could be the catalyst for a major reshoring boom. Exeter-based Rapid Fusion Ltd, which has enjoyed significant success with its Apollo and Zeus additive manufacturing (AM) platforms, will showcase its huge ‘Medusa’ at a special Open Day on 26 February at its Skypark R&D centre in Exeter.

The company has tapped into a £1.2 million grant from Innovate UK to develop, test, design and build the industrial 3-D printer, which is three-times faster than conventional machines, twice as accurate, and promises to reduce training and maintenance costs by 30%.

Backed by project partners Rolls-Royce, AI Build and the National Manufacturing Institute Scotland (NMIS), the gantry-style machine combines pallet extruder, filament and CNC machining tool to provide a single-source solution for large moulds and tooling that is typically used by aerospace, automotive, marine and construction companies. The latest AI technology has been integrated into the design, with Medusa boasting a 1.2m³ volume build and able to move at 1,200mm/sec speeds.

Rapid Fusion has already received significant interest from Tier Ones and several primes for the £500,000 machine and are predicting a potential £5 million revenue return in the first year following launch. Martin Jewell, Rapid Fusion’s chief technical officer, said: “After 18 months in the making, this will be a real landmark moment for AM in the UK. A factory-ready industrial 3-D printer that is built in the UK and is faster than any international rival is a tremendous achievement and has only been made possible by our engineering expertise and the strong collaboration with Rolls-Royce, AI Build and the NMIS.”

He continued: “The funding from Innovate UK made the extensive R&D possible, and we now have a machine that, thanks to features like a built-in tool changer, can produce large moulds faster, more efficiently and more accurately than anything currently out there. This could be the catalyst for many domestic companies to reshore production — it could have that big an impact on manufacturing performance and cost points.”

Live demonstration
More than 150 people are expected to attend the official launch of Medusa at Rapid Fusion’s facility in Exeter, with keynote speeches expected from industry leaders and project partners. The AM platform, which includes predictive maintenance, thermal modelling and the latest computer vision system, will be put through a live demonstration including the creation of a large mould that can be used to produce components for the aerospace sector.

Jake Hand, managing director of Rapid Fusion, said: “The UK has traditionally been behind other major economies when it comes to large-format AM. What we have done through the development and launch of Medusa is to democratise high-value, environmentally responsible manufacturing to both large and small businesses. We saw during the Covid-19 pandemic how easily supply chains can crumble. That is why it is more important than ever to develop as much capacity and capability in the UK as we can, not to mention the economic and carbon reduction opportunities associated with having a thriving 3-D printing sector implementing the latest available green technologies.”

Sampan, Seth, Additive Manufacturing Team Lead — Digital Factory at NMIS, added: “The conclusion of this project and the delivery of the first UK-built large-format robust polymer 3-D printer is a significant step forward in positioning the UK as a leader in this field. We were proud to support Rapid Fusion and the wider consortium with our range of specialisms during the project – it is a great demonstration of what can be achieved through collaboration between academic expertise and industry knowhow.”

Chaco van der Sijp, Innovate UK’s Innovation Lead Manufacturing, concluded: “The collaboration with industry partners and our High Value Manufacturing Catapult has resulted in the creation of an impressive all-in-one AM machine. This innovation aligns with our vision for a more adaptive and flexible UK materials and manufacturing sector. It has the potential to significantly accelerate the pace of innovation. By enabling rapid prototyping of large-scale components, it opens new opportunities for the sector and drives future advancements.”