Rapid Fusion is set to release Medusa, the UK’s first large-sized hybrid 3D printer

In February 2025, Rapid Fusion plans to officially launch its first domestically manufactured large-size hybrid 3D printer, Medusa, at an open day event held at the Skypark R&D center in Exeter on February 26. This industrial grade equipment cleverly combines additive manufacturing (i.e. 3D printing) and subtractive manufacturing (such as CNC machining) processes, specifically designed for the efficient production needs of large molds and tools in industries such as aerospace, automotive, shipbuilding, and construction.

Medusa’s research and development has received £ 1.2 million in funding support from Innovate UK, with strong support from renowned industry partners such as automotive giant Rolls Royce, 3D printing software company Aibuild, and the National Manufacturing Institute of Scotland (NMIS). The machine adopts a gantry structure design and integrates a particle extruder, filament based printing technology, and CNC machining functions. According to Rapid Fusion, Medusa is designed to run at a speed of 1200 mm per second and build a volume of 1.2 cubic meters. Compared to traditional systems, Medusa not only increases speed by three times, but also has higher accuracy, while effectively reducing training and maintenance costs. Medusa is also equipped with advanced features driven by artificial intelligence, such as predictive maintenance and thermal modeling, which help optimize the entire production process and improve product repeatability and consistency

It is expected that this unveiling event will attract over 150 professionals, including experts from various industries and representatives from partner institutions. Medusa will conduct a practical demonstration at the event site, demonstrating how to make large molds suitable for the aerospace industry, allowing the audience to intuitively experience the powerful functions of this advanced equipment. Currently, Martin Jewell, Chief Technology Officer of Rapid Fusion, is conducting final testing on Medusa to ensure everything is ready.

The development process of large-scale polymer 3D printing technology has been relatively slow, partly due to the relatively niche application scenarios, mainly concentrated in the field of large-sized tools (which is precisely the market that Rapid Fusion focuses on). With the growth of market demand, especially the increasing demand for carbon fiber layup molds and other specialized tools, companies like Caracol and 3D Systems have also discovered enormous potential in this field.

 

Although 3D Systems’ Titan series is Rapid Fusion’s most direct competitor, considering the demand for localized solutions in different regions around the world, each location requires more than one local manufacturer to meet various specific needs. Therefore, in order to enhance the resilience and redundancy of the supply chain, the UK needs to develop its own advanced manufacturing technology, which can not only better respond to market demand, but also promote the continuous innovation and development of the UK manufacturing industry.

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The 2025 Additive Manufacturing User Group (AMUG) conference

The 2025 Additive Manufacturing User Group (AMUG) conference is about to kick off: the perfect combination of automotive and additive manufacturing

The Additive Manufacturing User Group (AMUG) meeting for 2025 is scheduled to be held in Chicago, Illinois, USA, from March 30 to April 3, 2025 local time. This is an important event that brings together experts, scholars, and industry leaders in the global additive manufacturing field to discuss and share the latest developments, application cases, and future trends in 3D printing technology.

Joe Scarbo is about to step onto the AMUG conference stage to share his experience in the integration of racing engineering and cutting-edge manufacturing technology throughout his career. Scarbo’s career began with his love for cars and remote-controlled cars. He was a “mechanical maniac” since childhood, obsessed with dismantling toy cars and reassembling them, and also developed a strong interest in automotive sports. This passion drove him to study mechanical engineering at California State Institute of Technology Pomona and eventually became the chief chassis and suspension engineer for off-road racing projects at Volkswagen’s sports division.

 

Discovering the infinite potential of 3D printing

During this period, Scarbo accumulated rich practical experience and worked at a 3D printing service bureau. There, Scarbo first realized the enormous potential of this technology, especially after advances in materials science and manufacturing processes, where 3D printing gradually became a viable and powerful manufacturing tool. He recalled, ‘At that time, I learned about different manufacturing processes, how to use them, and what to expect from materials.’ At that time, materials were limited, but now technology has developed to the point where 3D printed parts can be practically used in the long run.

SV Rover: A Super Truck Achieved by 3D Printing

Scarbo’s latest masterpiece, the SV Rover, is the world’s first legally driven “super truck”. This model not only showcases the perfect combination of extreme off-road capability and high-performance engineering, but also highlights the key role of additive manufacturing in modern vehicle design. The SV Rover offers the option of a 1100 horsepower turbocharged V8 or a 1000 horsepower electric power system, with many 3D printed components integrated into its construction, such as stainless steel exhaust manifolds, complex suspension components, and aerodynamic elements. The design complexity of these components is extremely high, including internal cavities that are difficult to implement using traditional methods.

Scarbo successfully completed the Baha 1000 endurance race using 3D printed carbon filled nylon parts, proving the durability and reliability of 3D printed parts. By using 3D printing technology, Scarbo is able to design and produce with flexibility that traditional manufacturing cannot possess. For example, in the door components designed for an off-road truck, except for the original Land Rover door handles, the remaining components are all manufactured by the company itself, including SLS aluminum 3D printed hinges and carbon fiber exterior door panels. The car is equipped with a complex set of network components, including OEM lock devices, OEM window adjusters, and customized integrated speaker grilles. The speaker grille adopts SAF printing technology and is optimized for specific drivers. The FDM process allows for the construction of a completely sealed cavity inside the car door, providing ideal space for sound performance. If traditional manufacturing methods are used, such a design is almost impossible to achieve.

Customized solutions and market potential

For Scarbo, 3D printing is not only an indispensable part of the racing development process, but also plays a revolutionary role in prototype design and small batch production. Although 3D printing is not suitable for all scenarios, it performs exceptionally well in applications that handle complex geometries and small batch production, such as custom exhaust systems and suspension components. In addition, with the increasing demand for customized automotive components in the market, 3D printing provides fast iteration and low-cost solutions, particularly suitable for the needs of the aftermarket.

look into the future

At the AMUG 2025 conference, Scarbo will provide a detailed account of his exploration in the field of 3D printing and its impact on the future automotive industry. Whether it’s racing challenges on the track, extreme off-road in the desert, or daily driving on city streets, additive manufacturing has become an indispensable part of modern vehicle design. For the audience attending AMUG 2025, this is undoubtedly an opportunity to gain a deeper understanding of how 3D printing is reshaping modern vehicle design concepts. Let’s look forward to Scarbo’s wonderful speech together!

Regarding Scarbo Performance

Scarbo Performance was founded by Joe Scarbo in September 2008 as a design and manufacturing company that utilizes modern tools to produce competitive products. Its innovative design methods have been fully reflected in every product developed!

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The government held a symposium for private enterprises

The government held a symposium for private enterprises, with representatives from the Sharing Group and other companies participating in the production of a 10000 ton 3D printing intelligent factory for casting

On February 17, 2025, the government held a symposium for private enterprises, where many representatives of private enterprises gathered, including Huawei founder Ren Zhengfei, Alibaba founder Jack Ma, Xiaomi founder Lei Jun, as well as Peng Fan, chairman of Sharing Group Co., Ltd. and Sharing Intelligent Equipment Co., Ltd. This symposium provides an important communication platform for the development of private enterprises and is of great significance in promoting their sustainable and healthy development. CCTV conducted a key report.

It is reported that Share Group is a leading enterprise in China’s foundry industry, and its 3D printing technology and products have attracted much attention in recent years. The Sharing Group was founded in 1966 and has undergone multiple changes. Today, it has developed into a cross industry, cross regional, and diversified enterprise group. It is not only one of the leading industrial enterprises in Ningxia Hui Autonomous Region, but also outstanding in export earnings and taxes.

In the field of 3D printing, Shared Intelligent Equipment Co., Ltd., a subsidiary of Shared Group, has achieved remarkable results. The 3D printing full process intelligent factory for casting in Yinchuan is the world’s first 10000 ton level 3D printing intelligent factory for casting. Entering the factory, you can see 14 3D printers that are 5.2 meters high and weigh 35 tons neatly arranged in an air-conditioned workshop of about 4000 square meters. The floor is clean and tidy, with almost no dust, which is completely different from the traditional casting workshop environment. The factory controls the production process through an independently developed intelligent platform, achieving digital production. The overall equipment operation, including 3D printer execution, intelligent mobile cars, and stereoscopic warehouses, are all connected to intelligent units. The entire factory only has more than 30 workers, and the control room only requires 2 to 3 people per shift to control 14 3D printers, while traditional factories require at least 100 people to achieve the same production scale.

Shared Intelligent Equipment Co., Ltd. uses adhesive jet 3D printing technology. The principle is to “print” the cross-section of industrial components by spraying adhesive from the nozzle and stacking them layer by layer. It can be used for the production of products such as casting sand molds, metal parts green bodies, ceramic parts green bodies, etc. Among existing 3D printing technologies, this technology has the highest efficiency and lowest cost, making it more suitable for industrial applications in the manufacturing industry. Taking silica sand products as an example, after inputting the three-dimensional dimensional information of the product into the system, it can be formed into a whole shape through thousands of layers of powder spreading and adhesive spraying, without the need for molds or processing, and can achieve mass production effect. Moreover, a 3D printer can produce multiple different models of products.

At present, shared intelligent equipment has a leading sales share in the global adhesive jet 3D printer market. Its 3D printers are not only supplied to the domestic market, but also sold in large quantities overseas. Since 2018, more than 300 industrial grade casting sand 3D printers have been sold both domestically and internationally, and offices have been established in Austria and Japan. The super sand mold 3D printing equipment developed by it shortens the casting production cycle by 70%, controls the accuracy within plus or minus 0.5mm, and has a production efficiency three to five times that of similar scale equipment abroad, while the cost and price are only half of imported equipment.

This private enterprise symposium is a great encouragement for private enterprises such as the Sharing Group that are actively exploring in the field of technological innovation. In the future, the Sharing Group is expected to leverage policy support and its own technological advantages to continuously innovate in the field of 3D printing, promote industry development, and contribute greater strength to the transformation and upgrading of China’s manufacturing industry.

In 2024, China’s 3D printing output value will reach nearly 50 billion yuan

In December 2024, the Equipment Industry Department of the Ministry of Industry and Information Technology released a report titled “High Quality Development of the Equipment Industry Reaches a New Level”, which mentioned the progress made in the additive manufacturing industry in 2024 in the strategic emerging industries section. In addition, new energy vehicles, robots, industrial mother machines, rail transit, medical equipment, etc. have all reached new heights.

Promote the research and large-scale application of additive manufacturing equipment, systematically formulate and promote typical cases of process requirements, and carry out industry specific production and demand matching. Establish a sub standard committee for additive manufacturing processes and improve the standard testing system. It is expected to achieve a revenue of over 50 billion yuan in 2024, with a year-on-year growth of about 25%. From January to October, the export value was 7.89 billion yuan, maintaining a growth rate of over 50% for two consecutive years. 43 additive manufacturing medical devices have been registered with the National Medical Products Administration, and 120 have been registered as Class II products. Annual production of millions of additive manufacturing mobile phone hinges in the consumer electronics field.

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Key reasons to use SLA 3D printing

SLA (Stereolithography) 3D printing is preferred when high precision, smooth surface finish, intricate details, and tight dimensional tolerances are required, making it ideal for creating prototypes, jewelry, dental models, and other applications where accuracy and fine features are crucial; it also offers faster printing speeds compared to other technologies like FDM, thanks to its laser-curing process.

Key reasons to use SLA 3D printing:

High Accuracy and Detail:
Produces parts with exceptionally fine details and smooth surfaces, ideal for complex geometries and intricate designs.
Tight Tolerances:
Offers superior dimensional accuracy compared to other 3D printing methods, ensuring precise fit and function.
Fast Printing Speed:
Curing resin with a laser allows for relatively quick build times, especially for smaller, complex parts.
Wide Material Variety:
Access to a diverse range of resins with different properties like flexibility, rigidity, transparency, and biocompatibility, enabling customization for specific applications.
Prototyping Excellence:
Perfect for creating functional prototypes with high fidelity to the final design, allowing for accurate testing and refinement.

Common applications of SLA 3D printing:

  • Jewelry making: Creating intricate jewelry designs with precise details
  • Dental models and implants: Producing accurate dental models and surgical guides
  • Medical devices: Prototyping complex medical components with precise features
  • Microfluidics: Fabricating intricate microfluidic channels for research applications
  • Casting patterns: Creating high-quality molds for casting metal or other materials
  • Presentation models: Producing visually appealing models with smooth surfaces for design presentations
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Key reasons to use SLA 3D printing

SLA (Stereolithography) 3D printing is preferred when high precision, smooth surface finish, intricate details, and tight dimensional tolerances are required, making it ideal for creating prototypes, jewelry, dental models, and other applications where accuracy and fine features are crucial; it also offers faster printing speeds compared to other technologies like FDM, thanks to its laser-curing process.

Key reasons to use SLA 3D printing:

High Accuracy and Detail:
Produces parts with exceptionally fine details and smooth surfaces, ideal for complex geometries and intricate designs.
Tight Tolerances:
Offers superior dimensional accuracy compared to other 3D printing methods, ensuring precise fit and function.
Fast Printing Speed:
Curing resin with a laser allows for relatively quick build times, especially for smaller, complex parts.
Wide Material Variety:
Access to a diverse range of resins with different properties like flexibility, rigidity, transparency, and biocompatibility, enabling customization for specific applications.
Prototyping Excellence:
Perfect for creating functional prototypes with high fidelity to the final design, allowing for accurate testing and refinement.

Common applications of SLA 3D printing:

  • Jewelry making: Creating intricate jewelry designs with precise details
  • Dental models and implants: Producing accurate dental models and surgical guides
  • Medical devices: Prototyping complex medical components with precise features
  • Microfluidics: Fabricating intricate microfluidic channels for research applications
  • Casting patterns: Creating high-quality molds for casting metal or other materials
  • Presentation models: Producing visually appealing models with smooth surfaces for design presentations
/by

Key reasons to use SLA 3D printing

SLA (Stereolithography) 3D printing is preferred when high precision, smooth surface finish, intricate details, and tight dimensional tolerances are required, making it ideal for creating prototypes, jewelry, dental models, and other applications where accuracy and fine features are crucial; it also offers faster printing speeds compared to other technologies like FDM, thanks to its laser-curing process.

Key reasons to use SLA 3D printing:

High Accuracy and Detail:
Produces parts with exceptionally fine details and smooth surfaces, ideal for complex geometries and intricate designs.
Tight Tolerances:
Offers superior dimensional accuracy compared to other 3D printing methods, ensuring precise fit and function.
Fast Printing Speed:
Curing resin with a laser allows for relatively quick build times, especially for smaller, complex parts.
Wide Material Variety:
Access to a diverse range of resins with different properties like flexibility, rigidity, transparency, and biocompatibility, enabling customization for specific applications.
Prototyping Excellence:
Perfect for creating functional prototypes with high fidelity to the final design, allowing for accurate testing and refinement.

Common applications of SLA 3D printing:

  • Jewelry making: Creating intricate jewelry designs with precise details
  • Dental models and implants: Producing accurate dental models and surgical guides
  • Medical devices: Prototyping complex medical components with precise features
  • Microfluidics: Fabricating intricate microfluidic channels for research applications
  • Casting patterns: Creating high-quality molds for casting metal or other materials
  • Presentation models: Producing visually appealing models with smooth surfaces for design presentations
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