Rapid Fusion has partnered with Phoenix Analysis and Design Technologies (PADT) to introduce its robotic additive manufacturing systems to aerospace and defense customers in the United States. The collaboration marks the UK-based company’s first expansion into the U.S. market.
Rapid Fusion projects about $2.5 million (£2 million) in potential revenue during the first year, focusing on customers across the western United States. The company will promote its Apollo, Zeus, and Medusa robotic 3D printing systems, designed to reduce production time and operating costs compared with conventional methods.
The partnership will begin by targeting PADT’s existing clients. Rapid Fusion will use PADT’s technical expertise, manufacturing network, and 30 years of experience to mark a presence in the U.S. market.
Jake Hand, managing director at Rapid Fusion, said: “We have had significant success disrupting the large format additive manufacturing (LAFM) arena in the UK and Europe and felt it was time to push into the United States – a sector that is the biggest in the world for our technology,” Hand said.
“We needed to find the right partner who not only understood our values and our products but also had immediate access to clients who would benefit from our solutions. Initial conversations with PADT founder Rey Chu got us really excited, and we’re delighted to sign the deal that makes the company our first US reseller.”
“Phoenix Analysis and Design Technologies will have access to our full portfolio, including Apollo (a full turnkey 3D robotic printer), Zeus (a 3D printing robot that incorporates a unique CNC milling capability) and Medusa.”
“The latter is a real LFAM gem and is three times faster than conventional machines, twice as accurate and promises to reduce training and maintenance costs by 30%.”
PADT plans to hire a Rapid Fusion sales specialist. The company also plans to install Rapid Fusion’s robotic 3D printers at its Tempe facility. PADT will use its business-to-business marketing and sales network to reach aerospace and defense customers, then expand to the automotive, construction, and medical sectors.
Potential customers will start with a consultation and application review. Approved projects will move into a pilot phase to measure ROI. Based on initial results, customers can purchase a commercial system that includes installation, training, and support.
“Rapid Fusion’s pellet extrusion and robotic arm-based 3D printing systems offer a complementary and disruptive alternative to our current additive manufacturing offerings, enabling new applications in aerospace, construction, motor vehicles, and tooling,” added Rey Chu, a PADT principal and 3D printing pioneer at Phoenix Analysis and Design Technologies.
“With a 100,000-strong marketplace on the West coast alone there is so much potential to disrupt the US marketplace, and we are looking forward to accelerating the UK firm’s presence here. The key will be getting the first customers on board and then we have a fantastic test case to entice more companies to adopt the technology.”
Jake concluded: “USA is the largest country globally for additive manufacturing and a strategic part of our expansion plans. We conservatively forecast around £2m of revenue in the first 12 months and then, over time, for it to grow to become our largest territory.”
In addition to its U.S. expansion, Rapid Fusion has introduced an AI print assistant called “Bob (Base of Build).” The system, developed over eight months, uses AI to improve robot control, reduce downtime, and simplify operation. It will be deployed to existing customers in the automotive, aerospace, construction, medical, and defense sectors.
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 PADT
PADT Inc., founded in 1994 and headquartered in Tempe, Arizona, provides engineering services and products focused on simulation, product development, and 3D printing. The company serves industries including aerospace, automotive, medical, consumer goods, and manufacturing. PADT also acts as a reseller and consulting partner for software and hardware providers such as Ansys. With more than 90 employees and multiple offices across the United States, the firm supports customers through design, analysis, and additive manufacturing expertise.