Rapid Fusion has unveiled an AI print assistant that will help enhance the performance of its robotic additive manufacturing (AM) systems. Based in the southwest, the technology specialist’s team of developers leveraged the power of AI to optimise solutions for customers printing complex components for the automotive, aerospace, construction, medical and military sectors.

After eight months of coding, troubleshooting and various live tests, ‘BoB (Base of Build)’ is rolling out to existing clients and promising to optimise their robots by making them easier to use, providing greater operator control and ensuring less downtime through preventative maintenance.

The pre-loaded knowledge bank, anticipated to be one of the largest collections of 3D printing expertise ever created, functions in both secure online/cloud-connected and offline/air-gapped configurations for military or IP-sensitive clients. This works with Rapid Fusion’s existing models like Apollo and Zeus and for its most recent system, Medusa, the first UK-built large-format hybrid 3D gantry printer.

“There’s a lot of talk about how AI can transform the business world and numerous companies are jumping on the bandwagon,” explains Martin Jewell, CTO at Rapid Fusion. “It’s something we’ve been aware of from day one and all of our robotic AM systems have been built so that we can use AI to unleash the full potential of our technology.”

He continues: “Having our own AI print assistant is a gamechanger and will cut machine downtime and boost efficiency. We’re teaching our systems to understand challenges and different scenarios, which means we can make the user interface more responsive and simpler to embrace – opening it up to all the workforce. In essence, if we can make our systems as ‘plug and play’ as possible it means we’ll have more adopters.”

More information www.rapidfusion.co.uk

A project using large-scale additive manufacturing (AM) to produce shipbuilding components has completed its second phase, with results showing strong potential to reduce greenhouse gas emissions, secure supply chains and deliver significant economic benefits for the maritime sector. The project’s redesigned metal component – a topology optimised tapping ring – delivered a 10% reduction in emissions, cut lead times by 90% and reduced vessel weight by 13% in testing.

Led by Glasgow-based Malin Marine Consultants (MMC), part of Malin Group, with support from the National Manufacturing Institute Scotland (NMIS) – operated by the University of Strathclyde – Marine Vessel Lightweighting (MariLight) 2.0 builds on an initial feasibility study aimed at shifting the sector away from traditional manual fabrication towards automated, flexible and environmentally friendly manufacturing approaches.

The redesigned part underwent rigorous hydrostatic and leak testing under sustained pressure, which project partner Lloyd’s Register witnessed to ensure independent verification of the tests – a crucial step towards wider sector adoption.

The tapping ring was manufactured using Direct Energy Deposition-Arc (DED-Arc) technology at NMIS’s Digital Factory – an AM process that builds metal parts layer by layer using advanced welding techniques. This enabled local, on-demand production of lighter, optimised components with minimal material waste.

Other project partners included BAE Systems, Caley Ocean Systems (part of the Pryme Group), Siccar, Altair and Hexagon Manufacturing Intelligence. Altair produced the topology-optimised design for the tapping ring using its design optimisation software (Altair Inspire and Altair Optistruct).

Hexagon provided advanced computational modelling solutions, simulating the DED-Arc process and assessing factors such as temperature gradients and distortion prediction, while Siccar delivered a secure data-sharing platform, enhancing supply chain transparency through data traceability and real-time access to verified information.

More information www.nmis.scot

Listed among the leading universities in the UK, the University of Surrey is committed to innovation and maintaining its position as a top institution for higher education. At the forefront of that ambition is the Faculty of Engineering, which continues to enhance its offering to students by integrating the latest technological advancements into its teaching. By partnering with SYS Systems, the University of Surrey has invested in Stratasys additive manufacturing technology to provide learners with state-of-the-art equipment for producing realistic, functional components.

While a selection of desktop 3D printers had previously provided students with some exposure to the technology, but both staff and students were looking for a more professional solution.

The University of Surrey invested in two Stratasys 3D printing systems, initially the Objet30 Prime as part of a trade-in for a legacy machine, followed by the J55, both of which use PolyJet technology to deliver high levels of part accuracy and full-colour printing.

Design and engineering manager Myles Jenkinson says: “Our department is the School of Engineering, but the whole university makes use of the 3D printer. We’ve produced parts for the vet school based on MRI scans of animal skulls and created moulds for other departments. The smooth surface finish from the PolyJet printer is perfect for those kinds of applications. Additive manufacturing here is not just about supporting the university; we also have companies reaching out to us to access the technology because what we have is genuinely state-of-the-art. I would definitely recommend SYS Systems to other universities.”

More information www.sys-uk.com