Rapid Fusion, a UK-based robotic 3D printing company, is expected to showcase the ‘Medusa’ 3D printer on 26 February at its Skypark R&D center, in Exeter. The company has tapped into a £1.2m grant from Innovate UK to develop, test, design, and build the industrial 3D printer, which is 3x faster than conventional machines, 2x 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 a pellet extruder, filament, and a CNC machining tool to provide a single-source solution for large molds and tooling 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 build volume and the ability to move at 1,200mm per second.v

Rapid Fusion has reportedly already received significant interest from tier-one suppliers and several prime contractors for the £500,000 machine, and is predicting a potential £5m revenue return in the first year after launch.

“After eighteen months in the making, this will be a real landmark moment for additive manufacturing in the UK,” said Martin Jewell, Chief Technical Officer at Rapid Fusion. “A factory-ready industrial 3D 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 National Manufacturing Institute Scotland. 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 molds faster, more efficiently, and more accurately than anything currently out there. This could be the catalyst for many domestic companies to bring production back – it could have that big an impact on manufacturing performance and cost points.”

More than 150 delegates 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 modeling, and the latest computer vision system, will be put through a live demonstration including the creation of a large mold that can be used to produce components for the aerospace sector.

“The UK has traditionally been behind other major economies when it comes to large format additive manufacturing. What we have done through the development and launch of Medusa is to democratize high-value, environmentally responsible manufacturing to both large and small businesses,” said Jake Hand, Managing Director of Rapid Fusion. “We saw during the pandemic how easily supply chains can crumble. That’s why it’s 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 3D printing sector implementing the latest available green technologies.”

“The conclusion of this project and the delivery of the first UK-built large format robust polymer 3D printer is a significant step forward in positioning the UK as a leader in this field,” said Sampan Seth, Additive Manufacturing Team Lead for the Digital Factory at NMIS. “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 know-how.”

“The collaboration with industry partners and our High-Value Manufacturing Catapult has resulted in the creation of an impressive all-in-one additive manufacturing machine. This innovation aligns with our vision for a more adaptive and flexible UK materials and manufacturing sector,” said Chaco van der Sijp, Innovation Lead Manufacturing at Innovate UK. “This 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.”