Large-Format 3D Printing. Built in Britain. Available Across America.

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.

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85%

Faster than traditional tooling

4 Days

Typical delivery

60%

Cost Reduction

204°C

Max temperature

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Proven Results

Complex geometries impossible with machining

Complex geometries impossible with machining

Direct CAD-to-production workflow

Direct CAD-to-production workflow

204°C

Temperature resistance up to 400°F/204°C

±0.1mm dimensional tolerance

±0.1mm dimensional tolerance

Our Advanced Mold Creation Process

Four-stage proven methodology delivering production-ready tooling

Process Grid
1

Design & Engineering Optimization

Complete CAD integration and thermal analysis for optimal performance

  • Direct import from SolidWorks, NX, CATIA
  • FEA thermal simulation for shrinkage prediction
  • DfAM optimization for LFAM benefits
  • Complete thermal analysis workflow
2

Intelligent Material Selection

Expert selection from comprehensive Dahltram material range

  • Process temperature matching (65°C to 204°C)
  • Mechanical load analysis
  • Production volume optimization
  • Surface quality requirements
3

Hybrid Manufacturing Excellence

Zeus/Medusa production with integrated CNC finishing

  • Large-format printing with real-time monitoring
  • Optimised bead placement for strength
  • Continuous thermal and dimensional tracking
  • Integrated CNC milling to ±0.1mm tolerances
4

Professional Surface Preparation

Complete finishing system for production-ready tools

  • ToolPrep Solo primer application
  • Print-Seal treatment for release properties
  • Tool Valve installation for vacuum bagging
  • Dimensional inspection and validation
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How We've Solved Traditional LFAM Tooling Challenges

Addressing the five critical limitations that have held back 3D printed tooling adoption

Material Limitations

Problem: Limited temperature and strength options

Solution: Dahltram range from 65°C to 204°C

Benefit: Aerospace-grade materials including PEI and PESU for extreme conditions

Surface Finish Quality

Problem: Poor finish requiring heavy post-processing

Solution: Hybrid manufacturing with CNC finishing

Benefit: Ra 6.3μm finish using ToolPrep Solo for production-ready surfaces

Dimensional Accuracy

Problem: Materials fail at high process temperatures

Solution: Proven materials tested to service conditions

Benefit: Dahltram I-350CF and U-350CF deliver 204°C performance for demanding applications

Thermal Management

Problem: Tools wear out too quickly

Solution: High-strength materials with professional finishing

Benefit: Carbon fibre reinforcement and surface treatment extend tool life to production volumes

Proven Applications & Success Stories

Real-world results across multiple industries and applications

Compression Molds

Compression Molds

Automotive body panels and bumpers

Aerospace wing sections and fairings

Consumer product housings

Large-format packaging tools

Case Study: Malcom Nicholls car bonnet mold - 4 days vs 4 weeks traditional, 60% cost savings

Transfer & Injection Molds

Transfer & Injection Molds

Rubber component production

Medical device housings

Multi-cavity production tooling

Precision dashboard components

Material Recommendation: Dahltram C-250CF optimal for thermal cycling performance

Composite Layup Tooling

Composite Layup Tooling

Aerospace structural components

Automotive carbon fibre panels

Marine hull sections

High-temperature autoclave tools

High Temp Option: Dahltram I-350CF for autoclave applications up to 204°C

Vacuum Forming Tools

Vacuum Forming Tools

Large-format thermoforming

Automotive interior trim

Architectural facade panels

Custom packaging solutions

Integration: Tool Valve 125/150 for professional vacuum connections up to 260°C

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Join manufacturers already saving 85% on production time with our proven LFAM mold services

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