Rapid Fusion Expands to the U.S. with Robot-Based 3D Printing Technology

The UK-based company Rapid Fusion, specializing in large-format additive manufacturing, is expanding into the U.S. market. Together with its American partner Phoenix Analysis and Design Technologies (PADT), the Exeter-based company aims to establish its robot-based 3D printing systems in the aerospace and defense industries. The goal is to meet the growing demand for automated and scalable production solutions.

Jake Hand, Managing Director at Rapid Fusion, commented: “We have had significant success disrupting the large format additive manufacturing (LAFM) arena in the UK and Europe and felt it was time to push into the United States – a sector that is the biggest in the world for our technology. We needed to find the right partner who not only understood our values and our products but also had immediate access to clients who would benefit from our solutions. Initial conversations with PADT founder Rey Chu got us really excited, and we’re delighted to sign the deal that makes the company our first US reseller. Phoenix Analysis and Design Technologies will have access to our full portfolio, including Apollo (a full turnkey 3D robotic printer), Zeus (a 3D printing robot that incorporates a unique CNC milling capability) and Medusa. The latter is a real LFAM gem and is three times faster than conventional machines, twice as accurate and promises to reduce training and maintenance costs by 30%.”

Rapid Fusion operates a demonstration center in the UK with a team of ten employees and focuses on large-format 3D printing systems that process plastic pellets via robotic arms. Under the new distribution partnership, PADT gains access to the full product range, including the Apollo, Zeus, and Medusa systems. Apollo is a complete 3D printing cell, Zeus adds an integrated CNC milling function, and Medusa is recognized for its exceptional speed and precision — achieving up to three times the production rate of standard machines, according to Rapid Fusion.

“Rapid Fusion’s pellet extrusion and robotic arm-based 3D printing systems offer a complementary and disruptive alternative to our current additive manufacturing offerings, enabling new applications in aerospace, construction, motor vehicles, and tooling,” added Rey Chu, a PADT Principal and 3D printing pioneer at Phoenix Analysis and Design Technologies. With a 100,000-strong marketplace on the West coast alone there is so much potential to disrupt the US marketplace, and we are looking forward to accelerating the UK firm’s presence here. The key will be getting the first customers on board and then we have a fantastic test case to entice more companies to adopt the technology.”

Hand concluded: “USA is the largest country globally for additive manufacturing and a strategic part of our expansion plans. We conservatively forecast around £2m of revenue in the first 12 months and then, over time, for it to grow to become our largest territory.”

In parallel with its market expansion, Rapid Fusion has introduced an AI-driven software platform called “Bob – Base of Build”, designed to automatically optimize production parameters, reduce downtime, and simplify operations. Following an eight-month development phase, the system is now being gradually implemented among existing customers. The company expects to generate approximately £2 million in U.S. revenue in its first year and aims to make the market its largest territory over time.