Rapid Fusion and Applied Automation have extended their two-year collaboration with a new agreement focused on advancing Medusa, a UK-developed large-format hybrid 3D printer, into scalable production.
This will see engineering teams from the two companies join forces to turn the ‘prototype’ into a machine ready for shopfloor use, with interest coming from companies involved in the automotive, aerospace, construction, medical and renewables sectors.
Design for manufacture and supply chain management will be the first tasks, whilst Applied Automation experts will also create an assembly line and testing area at its facility in Plymouth to help ensure the target of an early 2026 release is met.
This technology is expected to generate more than £5m of revenue from first year sales and could create up to ten jobs across the two firms.
“We are fantastic at innovating and developing new technology that is changing the way companies adopt additive manufacturing,” explained Martin Jewell, chief technical officer of Rapid Fusion.
“However, we are not set-up to manufacture the solutions we create in low to medium volumes, which is where our relationship with Applied Automation really comes into its own. Our initial robot systems – Apollo and Zeus – have been developed in partnership so it made perfect sense to give Paul and his team the opportunity to build Medusa.”
“The aim is to take some of the early production costs out of the equation by streamlining design for manufacture and then developing an assembly line that will take just six weeks – from start to finish – to build each model. This gives us a great opportunity to be first to market and live on shopfloors by March 2026.”
Backed by a £1.2m grant from Innovate UK, Medusa is three times faster than conventional machines, twice as accurate, and promises to reduce training and maintenance costs by 30%.
The gantry-style machine integrates a pellet extruder, filament system, and CNC tool to offer a combined setup for producing large molds and tooling that is used by aerospace, automotive, marine and construction companies.
AI and Siemens motion control technologies have been integrated into the design, with the system boasting a 1.2m3 volume build and able to move at 1200mm per second speeds.
Paul Rowe, director of Applied Automation, continued: “Our job is all about taking fantastic technology and working out how we can serialize it at a cost and speed that works for Rapid Fusion and, importantly, the marketplace.”
“The facility in Plymouth is packed full of equipment and over 200 control system experts, toolmakers and manufacturing professionals that all work together to help bring the outsourcing process to life for customers.”
He went on to add: “For Martin and his team, we will take on most of the build, final assembly and testing. The aim is to have two pre-production machines ready in the next few months to help fine-tune the process, followed by the first commercial systems to be ready in the first quarter of 2026.
“Compliance is really important for Medusa and, by tapping into our service, it immediately gives the machine approvals with CE marking and UL508a, the latter is so important for the North American market.”
Jake Hand, managing director of Rapid Fusion, concluded: “This is the first time an industrial printer of this speed and size has been made in the UK, so we’re delighted to keep serial production on these shores and even better in the Southwest.
“Applied Automation is a world class manufacturing partner and will play a pivotal role in helping us hit £5m sales from Medusa in the first year. This is just the start, as we’ve also just agreed reseller agreements in new parts of the globe – this could accelerate revenues very quickly.”
Source: Rapid Fusion
About Rapid Fusion
Rapid Fusion Ltd, established in 2023 and based in Exeter, UK, develops large-format additive manufacturing (LFAM) systems for polymer-based applications. Its product portfolio includes pellet extrusion hardware and robotic 3D printing systems such as Apollo, Medusa, and Zeus, which are designed for high-speed, high-temperature printing. These solutions are used in aerospace, automotive, construction, marine, energy, and design sectors. The company manufactures its equipment in the UK and operates a 5,000-square-foot demonstration facility at Skypark for product trials and customer engagement. Rapid Fusion reported first-year revenue of approximately £1.7 million. The company has received support from Innovate UK and collaborates with industry partners to expand its product capabilities and market reach. Its technology focuses on scalable, efficient production of large polymer parts using pellet-based 3D printing integrated with industrial robotics.
About Applied Automation
Applied Automation (UK) Ltd, founded in 1985 and based in Plymouth, Devon, provides automation and control solutions for sectors including manufacturing, marine, and smart home technologies. Its business is structured across divisions covering industrial engineering, materials handling, technical distribution, marine automation, and home automation systems. The company also develops and supplies robotic and motion control products. Applied Automation employs approx. 176 people and operates two manufacturing sites in Plymouth and a distribution center in Cardiff. As of March 2024, it reported an annual revenue of around £23.7 million. The company serves both domestic and international clients and focuses on tailored automation solutions to meet specific operational needs. Its approach integrates engineering and component supply to enhance efficiency, integration, and quality across applications.