3D PRINTING
ENGINEERING COMPANY LAUNCHES HYBRID 3D PRINTER
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ngineering specialist, Sheffield Forgemasters, has launched a large-scale hybrid 3D Printer and Milling Machine to radically improve castings manufacture.
The new facility will manufacture patterns, the solid shapes which form the first critical stage of casting production. The patterns are used to make a sand and resin mould which liquid steel is poured into to create the casting.
The CEAD Flexbot 3D printer is a large-scale system, housed in a 14m x 8m x 5m enclosure. Robotic arm technology combined with 3D printing and milling uses both additive and subtractive technology to be able to create a wide range of complex patterns.
Michael Howson, senior development engineer Advanced Manufacturing Capability at Sheffield Forgemasters, says: “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.”
SYS SYSTEMS BOOSTS AM OFFERING O
Ashley Roberts, pattern shop manager at Sheffield Forgemasters, says: “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.” The state-of-the-art machine operates across two tables, one fixed and one rotating, can print up to 60kg of material per hour, and can use a range of fibre reinforce polymer materials to deliver large build volumes. Jason Barker, founder/CTO at CNC Robotics, which partners CEAD for UK distribution and maintenance, adds: “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.” The 3D printer has the potential to play a key role in boosting Sheffield Forgemasters’ productivity and consistency.
Sheffield Forgemasters
www.sheffieldforgemasters.com
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ne of the UK’s leading providers of additive manufacturing (AM) solutions is targeting a £multi-million opportunity after introducing new industrial scale, production- grade technology to its offering. Derby-based SYS Systems, a Platinum partner for the world’s biggest commercial 3D printing specialist Stratasys, will shortly be able to offer new and existing customers access to machines that print in metal and ceramics, complementing its core polymer range. This important move has been secured following a new deal between Stratasys and Tritone Technologies and will reduce barriers to AM adoption by delivering solutions ideal for end-use applications that need to be metallic for strength, conductivity and heat resistance. It also addresses the growing industrial requirement for serial production and manufacturing at scale.
“Applications for 3D printing are evolving so quickly, and we need to ensure we are offering technology that meets the different requirements of our customers, who are spread across multiple sectors, including aerospace, defence, medical devices and precision engineering,” explains Chris Fulton, managing director of SYS Systems. “The relationship that Stratasys has agreed with Tritone is a massive boost to our UK clients and means we can now add metal and ceramic technology to our core polymer offer, which is already producing parts for some of the world’s most critical applications.” He continues: “MoldJet is at the heart of the new range and is the only powder- free AM technology that enables a high throughput production of metal and ceramic parts at industrial scale and speed that has eliminated previous challenges. “It is designed for producing complex geometric components, with high density and industry standard mechanical properties. Changeovers are quick and parts of
different geometries and applications can be manufactured in the same batch.” SYS Systems, which is part of the Carfulan Group, is based in a £2.5m Advanced Innovation Centre in Foston, near Derby. From here, it showcases the technologies on offer from Stratasys, spanning FDM, Polyjet, P3 and SAF technologies, giving its diverse client base the ability to harness the full power of additive manufacturing to design, refine, iterate, create and manufacture next generation components.
The company offers much more than just the systems. Its team of experts, with hundred years of collective AM experience, work with businesses to uncover applications where 3D printing can offer significant savings in cost and time. Once identified, the client is supported in installation, training and ongoing help to maximise the capability of the solution. Fulton continues: “The industry is really splitting into two areas - low end ‘prosumer’ machines and ‘high-end industrial’. “SYS Systems is firmly in the industrial area where clients require reliability, repeatability and real support from humans! “It’s an approach that is really paying off. We have enjoyed significant growth in aerospace, defence, medical and the dental sectors, with the latter being transformed by a combination of the Stratasys J5 DentaJet printer and our patented TrueDentTM resin.” SYS Systems is part of the Carfulan Group, an advanced manufacturing specialist that has been helping industry work smarter, faster and more productive for over 35 years. The Derby-based company delivers a range of multi-senor metrology, 3D printing, tool presetting and shaft measurement solutions to SMEs, fast growth businesses and blue- chip companies, including JCB, JLR, Red Bull Powertrains and Rolls-Royce.
SYS Systems
www.sys-uk.com
Winter 2025/2026 UKManufacturing
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