Sheffield Forgemasters has invested in a large-scale hybrid 3-D printer and milling machine to radically improve casting manufacture. It will be used to manufacture patterns — the solid shapes which form the first critical stage of casting production. Patterns are used to make a sand and resin mould which liquid steel is poured into to create the casting. The new CEAD Flexbot 3-D printer is a large-scale system, housed in a 14 x 8 x 5m enclosure. Robotic arm technology combined with 3-D printing and milling uses both additive and subtractive technologies to create a wide range of complex patterns.
Michael Howson, senior development engineer, advanced manufacturing capability at Sheffield Forgemasters, said: “The launch of our CEAD Flexbot system will bring significant benefits to the manufacture of patterns at Sheffield Forgemasters. This system provides our pattern makers with an extra tool that, through autonomous operation, will allow staff to work on complementary activities during shifts and enable production to continue outside standard working hours, improving overall efficiency and capacity. It will reduce costs, shorten lead times for pattern production, and in turn improve delivery times for castings.”
Digital techniquesAshley Roberts, pattern-shop manager at Sheffield Forgemasters, said: “The introduction of this new capability will broaden our pattern-making skills to include digital techniques alongside established practices. The technology is already helping to develop the next-generation of pattern makers.”
The ‘state of the art’ machine operates across two tables, one fixed and one rotating, can 3-D print up to 60kg of material per hour, and can use a range of fibre-reinforced polymer materials to deliver large-build volumes.
Jason Barker, founder and CTO of CNC Robotics, which partners with CEAD for UK distribution and maintenance, said: “This hybrid large-format additive and subtractive capability is not just a technological upgrade, it is a step-change in how manufacturers like Sheffield Forgemasters can operate. By digitalising and automating aspects of traditional pattern manufacturing, the CEAD Flexbot enables faster turnround, higher repeatability, and greater design freedom.
“The system also supports more sustainable manufacturing. Additive deposition reduces waste material compared to conventional subtractive-only workflows, and the ability to recycle polymer feedstocks further strengthens the environmental benefits. We are excited to partner with Sheffield Forgemasters as it harnesses this technology to enhance capability, grow skills, and future-proof its pattern-making operations for decades to come.”