CNC and AM in one machine Rapid Fusion and Applied Automation team up to launch hybrid 3D printer

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A new manufacturing deal between Rapid Fusion and Applied Automation paves the way for the launch of Medusa, the UK’s first large-format hybrid 3D printer. Set for release in early 2026, the innovation targets high-demand sectors and is expected to generate over 5 million pounds in its first year.

One of the UK’s leading providers of robotic additive manufacturing systems has signed a new ‘outsourcing’ deal that will bring a world-first to market next year. In a match made in the South West, Rapid Fusion and Applied Automation have expanded a two-year business partnership by agreeing to work in tandem to productionise Medusa – a UK-built large format hybrid 3D printer.

This will see engineering teams from the two companies join forces to turn the ‘prototype’ into a machine ready for shopfloor use, with interest already coming from companies involved in the automotive, aerospace, construction, medical and renewables sectors.

Design for manufacture and supply chain management will be the first tasks, whilst Applied Automation experts will also create a dedicated assembly line and testing area at its facility in Plymouth to help ensure the target of an early 2026 release is met.

This new technology is expected to generate more than 5 million pounds of revenue from first year sales and could create up to ten jobs across the two firms.

“We are fantastic at innovating and developing new technology that is changing the way companies adopt additive manufacturing,” explained Martin Jewell, Chief Technical Officer of Rapid Fusion.

“However, we are not set-up to manufacture the solutions we create in low to medium volumes, which is where our relationship with Applied Automation really comes into its own. Our initial robot systems — Apollo and Zeus — have been developed in partnership so it made perfect sense to give Paul and his team the opportunity to build Medusa.

“The aim is to take some of the early production costs out of the equation by streamlining design for manufacture and then developing an assembly line that will take just six weeks — from start to finish — to build each model. This gives us a great opportunity to be first to market and live on shopfloors by March 2026.”

Medusa is backed by a 1.2 million pound grant from Innovate UK. The manufacturer claims that it is three times faster than conventional machines, twice as accurate and promises to reduce training and maintenance costs by 30 percent.

The gantry-style machine combines pellet extruder, filament and a 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.

Latest AI and Siemens motion control technologies have been integrated into the design, with the system boasting a 1.2 m³ volume build and able to move at 1,200 mm per second speeds.

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