Large-Format 3D Printing. Built in Britain.
Rapid Fusion's industrial additive manufacturing systems, Apollo, Zeus, Medusa, and Cerberus, are now available in the US through PADT, the Southwest's most trusted engineering and additive manufacturing partner. Trusted by engineers and manufacturers in aerospace, defense, automotive, energy, and more. Sold and supported by PADT, serving US manufacturers since 1994.
From concept models to functional prototypes - if you can design it, we can print it
Up to 2.5m³ printing envelope enables full-scale automotive panels, architectural models, and marine components.
Maximum dimensions: 2.5m x 2.5m x variable height
Continuous printing capability
No size-related assembly joints
From CAD file to finished prototype in 48-72 hours for most projects
Timeline:
File upload: Same day quote
Production start: Within 24 hours
Typical completion: 2-3 working days
Express service: available
Engineering-grade materials for real-world testing and validation
Dahltram T-100CF: Room temperature testing
Dahltram C-250CF: Elevated temperature validation
Multi-material options: Different properties in one print
Hybrid manufacturing delivers prototype-to-production quality
Quality:
±0.5mm dimensional accuracy
Ra 12.5μm surface finish achievable
CNC finishing for critical surfaces
Professional quality documentation
Transforming conventional designs for additive manufacturing excellence
Remove unnecessary material whilst maintaining or improving structural performance
Process: Load case analysis, Stress distribution mapping, Material removal optimization, Performance validation
Typical Results: 40-60% material reduction, improved strength-to-weight ratio
Redesign parts to eliminate or minimize support material requirements
Process: Overhang analysis, Print orientation optimization, Self-supporting feature design, Bridge and cantilever optimization
Typical Results: 70-90% support reduction, faster printing, better surface finish
Determine optimal part orientation for strength, quality, and speed
Process: Stress analysis in all orientations, Surface quality assessment, Support requirement evaluation, Build time optimization
Typical Results: 25-40% faster builds, improved surface quality
Optimise designs to leverage multiple materials in single prints
Process: Material property mapping, Interface design optimisation, Thermal expansion matching, Performance zone definition
Typical Results: Enhanced functionality, reduced assembly, improved performance
Combine multiple parts into single prints to reduce assembly
Process: Assembly analysis, Joint optimization, Tolerance stack-up evaluation, Functionality preservation
Typical Results: 50-80% part count reduction, elimination of fasteners
Add functionality impossible with traditional manufacturing
Process: Internal feature design, Lattice structure integration, Cooling channel optimization, Embedded feature design
Typical Results: Enhanced performance, reduced part count, novel functionality
Proven DfAM Methodology
Systematic approach to design optimization delivering consistent results
Complete CAD integration and thermal analysis for optimal performance
Expert selection from comprehensive Dahltram material range
Zeus/Medusa production with integrated CNC finishing
Complete finishing system for production-ready tools
Flexible Consultation Options
Choose the level of support that matches your project needs
Ready to Optimise Your Design?
Book a consultation to discover how DfAM can transform your manufacturing approach
