During the installation of Rapid Fusion's ZEUS hybrid manufacturing system at INNOV Advanced Materials Centre in Canada, we spoke with the team about their experience and the possibilities this technology unlocks.
In this customer testimonial, we explore how combining large-format additive manufacturing, 3D scanning and CNC milling can transform traditional mould manufacturing and prototyping workflows.
From producing a 3D printed component to scanning, aligning and machining it, the system brings multiple manufacturing processes together in one integrated workflow.
Rapid Fusion's ZEUS hybrid manufacturing system is helping INNOV Advanced Materials Centre in Canada explore faster, more efficient ways to produce moulds, prototypes and industrial components.
Traditional mould manufacturing can be a time-consuming process, often requiring multiple stages of production, manual alignment and separate equipment. By combining large-format additive manufacturing, 3D scanning and CNC machining, Rapid Fusion's ZEUS system brings these processes together into one integrated workflow.
Following the installation of ZEUS at INNOV Advanced Materials Centre in Canada, the Rapid Fusion team spoke with INNOV about the installation experience, the capabilities of the system and how it could change the way the organisation approaches manufacturing.
The Challenge: Reducing Lead Times in Mould Manufacturing
Producing industrial moulds and prototypes using conventional manufacturing methods can take weeks or even months, depending on the complexity of the component and the processes involved.
For INNOV, the opportunity was to explore how advanced manufacturing technology could accelerate production, allowing the team to move from a digital design to a physical component more efficiently.
A key consideration was the ability to manufacture moulds and prototypes while reducing the manual work associated with preparing, positioning and aligning components for machining.
The team also wanted a system that could be adapted to its specific requirements, providing flexibility for future customer projects.
The Solution: Rapid Fusion's ZEUS Hybrid Manufacturing System
To support these requirements, Rapid Fusion installed a customised ZEUS hybrid manufacturing system at INNOV.
ZEUS combines three manufacturing capabilities within an integrated workflow:
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Large-format additive manufacturing: Producing near-net-shape polymer components directly from digital CAD designs.
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3D scanning: Capturing the geometry of a printed or existing component to support alignment, modification and further manufacturing.
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CNC milling: Machining printed components to achieve the required geometry and surface finish.
By integrating these processes, ZEUS enables manufacturers to move between additive and subtractive manufacturing without relying on multiple standalone systems.
The installation was tailored to INNOV's requirements, with particular attention given to the scanning workflow.
Reflecting on the installation, the INNOV team explained:
"It was really, really customised for our needs and how we want to work with it."
From CAD to Mould in Just 12 Hours
One of the most significant demonstrations during the installation was the ability to progress from a CAD model towards a finished mould within a single working day.
During the training and installation process, the team began with a CAD model, produced a 3D printed component and aligned it in preparation for CNC milling.
The workflow demonstrated the potential to complete a process in approximately 12 hours that would traditionally take substantially longer.
As the INNOV team explained:
"For me, it's insane because usually, it would take weeks, months."
They also highlighted the wider implications for mould manufacturing:
"Mould manufacturing is something that takes weeks and months, while you see you can do it in a day. So for me, this is the big change."
Although the final milling stage was still to be completed at the time of the interview, the demonstration illustrated how integrated hybrid manufacturing could significantly reduce production lead times.
Simplifying CNC Alignment with 3D Scanning
An important part of the customised installation was the integration of 3D scanning into the manufacturing process.
Traditionally, aligning a printed component for CNC machining can require significant manual intervention. The component must be accurately positioned so that the machining software understands its real-world geometry and orientation.
With the ZEUS scanning workflow, the team can capture the geometry of an as-printed component and use that information to align it within the software.
During the demonstration, Rapid Fusion explained how this approach could reduce an alignment process from approximately one day to around 20 minutes.
Beyond machining alignment, INNOV also identified opportunities to scan existing components, modify their designs and use the resulting digital models to manufacture new moulds or prototypes.
This creates additional possibilities for reverse engineering, product development and customised manufacturing.
The Results: A More Integrated Manufacturing Workflow
The installation demonstrated several potential advantages for INNOV and its customers.
Faster mould production
The integrated workflow offers the potential to reduce processes that traditionally take weeks or months to approximately one day, depending on the application.
Reduced manual alignment
3D scanning and software-based alignment can substantially reduce the time required to prepare printed components for CNC machining.
Greater manufacturing flexibility
The ability to print, scan and mill within one system gives INNOV additional options for producing moulds, prototypes and customised components.
A system tailored to operational requirements
The installation was customised around INNOV's intended applications, particularly the integration of scanning into its manufacturing workflow.
New opportunities for customers
By accelerating the transition from CAD designs to physical components, the technology creates opportunities for faster prototyping and manufacturing services in Canada.
Looking Ahead: Supporting INNOV's Manufacturing Ambitions
The installation marks the beginning of INNOV's work with the ZEUS system.
With the equipment installed and initial training completed, the team is looking forward to applying the technology to future projects and exploring its capabilities with customers.
Speaking about the experience, the INNOV representative said:
"I'm very grateful for the experience I have so far, and I'm really, really excited to apply this system into our work in the future."
Rapid Fusion will continue supporting INNOV as the team develops its applications and builds experience with the system.
The collaboration demonstrates how combining additive manufacturing, scanning and CNC machining can help organisations rethink traditional production workflows and explore more efficient ways of manufacturing large-scale components.
Watch the Customer Testimonial
Hear directly from INNOV about its experience with Rapid Fusion, the ZEUS installation and the opportunities created by hybrid manufacturing.
Explore Hybrid Manufacturing with Rapid Fusion
Looking to reduce manufacturing lead times, accelerate prototyping or bring additive and subtractive manufacturing together?
Rapid Fusion develops large-format additive manufacturing and hybrid manufacturing systems designed to help businesses produce industrial components more efficiently.
