Introduction
Rapid Fusion is a UK leader in design, manufacturing and delivering Large Format Additive Manufacturing (LFAM) advanced robotic solutions. Our mission is to empower research institutions and industries to design and produce at scale, bridging the gap between concept and reality.
This case study explores how Rapid Fusion partnered with University College London (UCL),
University of Exeter, Manchester Metropolitan University, University of Bristol and University of Lancashire to upgrade their prototyping capabilities with the Zeus Hybrid Robotic Cell and PE320 extruder.
University Background
- UCL: A global top 10 university, supporting research in aerospace, architecture, and product design.
- University of Exeter: Known for excellence in engineering and material sciences, with a focus on composites and sustainability.
- Manchester Metropolitan University (MMU): A hub for applied research and industry collaboration, supporting construction, creative industries, and engineering design.
- University of Bristol: UOB is a research-intensive university with strong global reputation.
- University of Lancashire (UCLAN): A historic, internationally-oriented institution offering wide-ranging academic programs, modern facilities, and strong support for student employability and global engagement.
Challenge / Objectives
Universities faced restricted build volumes, slow production speeds, and limited material compatibility. Objectives included expanding prototype size, improving throughput, supporting advanced materials, and integrating with existing facilities.
Solution Provided
Rapid Fusion installed the Zeus Hybrid Robotic Cell with PE320 extruder, offering a 200%+ build volume expansion, multi-material capability, and modular upgrades. Systems were tailored for each university’s focus: aerospace and architecture at UCLAN with extended reach on moving rail, materials research at Exeter, and flexible industry projects at MMU.
Quotes / Testimonials
Martyn Carter, Operations Manager on behalf of UCL The Bartlett School of Architecture
“B-made Robotics at the Bartlett School of Architecture has recently invested in robotic 3D printing with pellet extrusion, as a transformative tool for design education and experimentation. Unlike traditional filament-based printing, pellet extrusion enables the use of a wider range of materials, the ability to mix material types and most importantly the use of recycled and waste plastics. We’ve experienced challenges with producing high quality recycled filaments and cutting out this stage, going directly from granule to print results for a more sustainable and cost-effective option for large-scale architectural prototypes. This flexibility allows students to explore material behaviour, structural performance, and environmental impact in ways that align with contemporary architectural challenges such as circular design and low-carbon construction.
Moreover, robotic 3D printing fosters a hands-on, interdisciplinary learning environment where architecture students engage with robotics, computational design, and digital fabrication. The integration of robotic arms and custom toolpaths encourages parametric thinking and iterative design, bridging the gap between conceptual modelling and real-world construction techniques. Where polymers aren’t always the desired final material, the production of moulds, jigs and prototypes plays a vital stage is the manufacturing process.”
Oana Ghita, Engineering research Chair on behalf of Exeter University
“Continuing to focus on High Temperature Polymers and Composites AM such as PEEK or PEI, the Centre for Additive Layer Manufacturing (CALM) at the University of Exeter invested into a Large Format AM system combined with LEAM, an intelligent modular thermal control technology integrated within the extruder head of the printer.
This allows the group to continue print with the high temperature polymers and composites in an open environment. The group has been working extensively on the simulation and validation of the thermal profile of these materials with and without localised heating. This step is critical in defining optimum print parameters for specific application needs.
The group is advancing their work on overprinting (printing onto composite or metallic complex structures), as well as large format printing for renewable energy applications such as wind turbine components.”
Tavs Jorgenson (Academic Lead for the Bridge Studios) on behalf of Bristol University
“Rapid Fusion developed and supplied a pellet-feed 3D printing system for integration with our large-scale industrial KUKA robotic arm. Rapid Fusion’s ability to deliver customised solutions for 3D-printed architectural scale components is central to enable our groundbreaking research. Equally, access to Rapid’s expertise and specialist knowledge is critical in helping us maintain a system at the forefront of industrial development in this emerging field.”
Dickon Walker NMIS (R&D Engineer) on behalf of the National Manufacturing Institute Scotland
“When are currently in the last stages on installation, we intend to use it for large tooling, jigs and fixtures for composites and machining applications. We would also like to investigate combining it with our Automatic Fibre Placement (AFP) cell to see what can be achieved with them as a pair. Industry is struggling with lead times, costs and sustainability. We intend to help bridge the gap with polymer LFAM mould tools, as a new process in production.”
Mark Chester (AM Lead) Print city on behalf of Manchester Metropolitan University
“PrintCity, Manchester Metropolitan University have invested in the Rapid Fusion PE320 Pellet Extruder which has been retrofitted onto an ABB Robot Cell donated by Autodesk. The facility purchased the pellet extruder as a way of increasing throughput of large 3D printed objects due to the increased feed rate of polymer. Additionally, the use of pellets reduces a processing step when looking to recycle polymer waste or components without having to extrude filament.
PrintCity is utilising the Rapid Fusion PE320 pellet extruder in a number of ways across research and in collaboration with industry. Within research, the facility is looking at how pellet extrusion can be used within a circular economy to repurpose polymer waster or components. This research can also explore the reduction of energy and carbon when analysing the processing polymers for pellet printing in comparison to FDM processes. Within industry, the facility is helping companies across a range of different sectors to explore pellet printing to see if the technology is suitable for their applications.”
Paul Critchley (Technical Manager) Workshops & Engineering on behalf of University of Lancashire
“University of Lancashire has prioritised the development of AM and robotics as the way forward. To that end, after a tender process which looked at all the main AM systems on the market suitable for usage with a robot arm, the Rapid Fusion PE320 was selected. There were a number of factors involved in that decision, but in a nutshell, it out performed it’s rivals in all the key measures. As you can see in the photographs, it has been paired with an ABB arm fitted to a track. This gives the PE320 the maximum coverage utilising the minimum amount of space.
This is a brand new installation, but has already attracted interest from many areas of the university, from aerospace engineering, through civil engineering to fine art and interior design. The university AM research team also has plans to utilise the PE320, because it’s pellet extrusion system allows considerable flexibility in the use of different materials, both from a performance perspective and from the point of view of the development of recycling technologies.”
AM Project Manager - Oliver Coleman
“At Rapid Fusion, my mission is to enable the next generation of large-scale, sustainable additive manufacturing through the development and deployment of high-performance pellet extrusion systems. We’ve successfully installed robotic additive manufacturing solutions across numerous leading UK academic and research institutions. These installations reflect a growing demand for scalable, flexible, and sustainable 3D printing technologies - particularly in the context of material circularity, design experimentation, and advanced manufacturing.
Our partners are leveraging these capabilities to explore circular economy principles, low-carbon construction, and material reuse at architectural scales.
Rapid Fusion’s solutions are also designed to integrate seamlessly with robotic arms, empowering users to create custom toolpaths and geometries that go beyond the limitations of gantry-based systems. This robotic flexibility supports advanced research in areas such as overprinting, mould-making, and the production of complex tooling for composites, as seen in collaborations with NMIS and CALM at the University of Exeter. More than just hardware, our work is about creating a platform for innovation. Across our university partnerships, we’ve seen first-hand how robotic additive manufacturing fosters interdisciplinary research, bringing together students and researchers from design, engineering, materials science, and sustainability. From enabling rapid prototyping of large-scale architectural components to advancing the use of polymers in tooling and industrial applications, Rapid Fusion’s technologies are helping institutions remain at the forefront of digital fabrication and manufacturing research.”
Implementation Process
- Planning: Site assessments and fit-checks.
- Installation: Compact footprint, minimal disruption.
- Testing: Benchmark trials with key materials.
- Commissioning: Staff/student training with ongoing support.
Results & Benefits
Quantitative Outcomes:
- Build volume increased by >200%
- Production speed improved by 40%
- Expanded uptime and reduced maintenance.
Qualitative Outcomes
- Students gained confidence in larger design projects.
- Researchers accessed new material capabilities.
- Universities enhanced reputation in digital fabrication.
Lessons Learned
- Early site survey sensure smooth installation.
- Close collaboration maximises adoption.
- Student involvement accelerates learning.
