U.S.-based company Phoenix Analysis and Design Technologies (PADT) has entered into a distribution partnership with U.K. manufacturer Rapid Fusion Ltd.. Through this collaboration, PADT expands its portfolio in large-format additive manufacturing (LFAM) and gains access to Rapid Fusion’s modular 3D printing systems. The goal of the partnership is to enhance production efficiency in industries such as aerospace, automotive, and energy while promoting more sustainable manufacturing processes.
Rapid Fusion specializes in large-format, robot-assisted 3D printing solutions in Europe. The partnership gives the company its first entry into the North American market, while PADT strengthens its industrial 3D printing capabilities — particularly in the sales and service of Stratasys systems — with new production capacities.
“We’ve supported aerospace and defense customers with LFAM for years, but they needed more larger-format systems, flexible robotics, and sustainable materials,” said Rey Chu, PADT Principal and 3D printing pioneer. “Rapid Fusion is disrupting the sector in the UK and Europe, delivering scalable, high-throughput solutions that exceed the limits of traditional gantry or filament-fed systems.”
Large-format additive manufacturing technology primarily relies on pellet-based extrusion, which uses plastic granules instead of filaments. This process enables higher material throughput and lower unit costs. Applications include the production of tools, molds, and architectural components.
Market analysts forecast strong growth for LFAM: the global market is expected to expand from around USD 118 million today to more than USD 600 million by 2030.
“When we met PADT’s leadership, we were impressed by their legacy and deep understanding of manufacturing,” said Jake Hand, Managing Director of Rapid Fusion. “Together, we’ll deliver modular 3D platforms, AM modules, and robotic AM cells that empower manufacturers to produce large, cost-effective components with high output and sustainability.”
The partnership marks a step toward a more automated and data-driven additive manufacturing landscape in North America.
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