The British companies Rapid Fusion and Applied Automation are intensifying their collaboration with the aim of bringing the large-format hybrid 3D printer Medusa into series production by early 2026. The printer, which currently exists as a functional prototype, will be available as an industrial-grade solution for applications in the automotive, aerospace, construction and medical industries. A dedicated production line at the Plymouth site and optimized processes for production preparation form the foundation of the joint initiative.
“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 based on a gantry structure and combines three technologies in one system: pellet-based extrusion printing, filament processing and CNC machining. The system is designed for a build volume of 1.2 cubic meters and achieves travel speeds of up to 1200 mm/s. The integration of the latest Siemens motion control solutions and AI-supported control algorithms should enable improved reproducibility and reduced set-up times.
Paul Rowe, Director of Applied Automation, picked up the story: “Our job is all about taking fantastic technology and working out how we can serialise it at a cost and speed that works for Rapid Fusion and, importantly, the marketplace. The facility in Plymouth is packed full of equipment and over 200 control system experts, toolmakers and manufacturing professionals that all work together to help bring the outsourcing process to life for customers.”
The collaboration with Applied Automation aims to reduce manufacturing costs through “design for manufacture” and establish a standardized assembly process.
He went on to add: “For Martin and his team, we will take on most of the build, final assembly and testing. The aim is to have two pre-production machines ready in the next few months to help fine-tune the process, followed by the first commercial systems to be ready in the first quarter of 2026. Compliance is really important for Medusa and, by tapping into our service, it immediately gives the machine approvals with CE marking and UL508a, the latter is so important for the North American market.”
Jake Hand, Managing Director of Rapid Fusion, concluded: “This is the first time an industrial printer of this speed and size has been made in the UK, so we’re delighted to keep serial production on these shores and even better in the South West. Applied Automation is a world class manufacturing partner and will play a pivotal role in helping us hit £5m sales from Medusa in the first year. This is just the start, as we’ve also just agreed reseller agreements in new parts of the globe – this could accelerate revenues very quickly.”
A pre-series of two machines is to be completed in the coming months in order to secure production processes and approval requirements such as CE marking and UL508a certification. Series production is then scheduled to start in the first quarter of 2026. The project is being funded with 1.2 million pounds by Innovate UK. Rapid Fusion expects sales of over five million pounds in the first year of sales.
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