Rapid Fusion

Rapid Fusion Ltd is a UK-based contract manufacturer at the forefront of large-format additive manufacturing (LFAM) for polymer components. Leveraging advanced robotic 3D printing and pellet extrusion, the company aims for global leadership in LFAM through innovation and strategic partnerships, supported by Innovate UK Smart grants and industry leaders like Rolls Royce and Baker Hughes. Their integrated robotic AM cells, including Apollo, Zeus, Medusa, and Cerberus, alongside their Additive Upgrade Kit and PE320 Pellet Extruder, are all Made in Britain certified.

The company offers comprehensive LFAM services, from full-scale prototypes to production-ready parts, including industrial tooling and moulds. Their advanced software suite, featuring AiBuild, automates and optimises the printing process with AI-driven error detection and quality control, ensuring fast, predictable, and repeatable production. Rapid Fusion's Zeus and Medusa systems, with integrated CNC finishing, achieve precision to ±0.1mm accuracy. They serve diverse sectors including Aerospace & Defence, Automotive, Construction, and Marine, providing scalable solutions for complex geometries, material performance, and supply chain challenges.

Rapid Fusion's Design for Additive Manufacturing (DfAM) services enhance part performance and reduce costs, offering massive build volumes up to 2.5m³ and rapid prototyping turnaround times of 48-72 hours. They deliver industrial tooling and moulds up to 85% faster and 60% cheaper than traditional methods, with lead times as short as 4 days, utilising high-temperature resistant materials. Case studies highlight their expertise in developing AI-designed vessels, 3D printed moulds, and enhanced concrete mould production. Key differentiators include UK-built excellence, cost-effective scaled production, complex design capabilities, sustainability focus, and an emergency 24-hour service.