Hybrid 3D printing and milling: Sheffield Forgemasters modernizes pattern production

The British industrial manufacturer Sheffield Forgemasters has commissioned a new hybrid 3D-printing and milling system to modernize the production of casting patterns. Patterns are a central element of the foundry value chain, as they form the geometric basis for sand and resin molds into which molten steel is later poured. Changes at this early process stage have a direct impact on quality, lead times, and costs across the entire manufacturing process.

A large-format system of the CEAD Flexbot type is being used, combining additive and subtractive processes. The system operates with a robotic arm in an enclosure measuring 14 by 8 by 5 meters and can both deposit material layer by layer and machine surfaces to defined tolerances. Printing is carried out with fiber-reinforced polymer materials that provide sufficient stiffness and dimensional stability for large-volume patterns. With a deposition rate of up to 60 kilograms per hour, even extensive geometries can be produced in a comparatively short time.

Michael Howson, Senior Development Engineer at Sheffield Forgemasters, sees organizational advantages above all. Automated operation allows employees to take on other tasks in parallel and enables production to continue outside regular shift hours.

“The launch of our CEAD Flexbot system will bring significant benefits to the manufacture of patterns at Sheffield Forgemasters. This system provides our Patternmakers with an additional 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. The new facility will reduce costs, shorten lead times for pattern production, and in turn improve delivery times for castings.”

Workforce qualification also plays a role. Pattern Shop Manager Ashley Roberts emphasizes that digital design and manufacturing methods are now being deliberately combined with traditional craft techniques.

“The introduction of this new capability will broaden our patternmaking skills to include digital techniques alongside established practices. The technology is already helping to develop the next generation of patternmakers.”

Jason Barker, Founder/CTO at CNC Robotics, which partners with CEAD for UK distribution and maintenance, said: “This hybrid large-format additive and subtractive capability isn’t just a technological upgrade, it’s a step-change in how manufacturers like Sheffield Forgemasters can operate. By digitising and automating aspects of traditional pattern manufacturing, the CEAD Flexbot enables faster turnaround, 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’re excited to partner with Sheffield Forgemasters as they harness this technology to enhance capability, grow skills, and future-proof their patternmaking operations for decades to come.”

Overall, Sheffield Forgemasters expects the hybrid system to deliver more stable and better-planned pattern production as the basis for consistent cast products.