Sheffield Forgemasters invests in hybrid 3D printer

A Sheffield-based engineering specialist has invested in advanced manufacturing technology to boost productivity and precision in casting production.

Sheffield Forgemasters has launched a large-scale hybrid 3D printer and milling machine designed to transform how casting patterns are produced. 

The new facility will manufacture the solid patterns used to create moulds for liquid steel, a critical early stage in the casting process.

The CEAD Flexbot system combines robotic arm technology with both additive and subtractive manufacturing, allowing complex patterns to be printed and milled in a single process. 

Housed in a purpose-built enclosure, the machine can print up to 60kg of material per hour and work with a range of fibre-reinforced polymer materials.

Bosses say the investment is expected to improve consistency, speed and efficiency across Sheffield Forgemasters’ casting operations.

Michael Howson, senior development engineer advanced manufacturing capability at Sheffield Forgemasters, said: “The launch of our CEAD Flexbot system will bring significant benefits to the manufacture of patterns at Sheffield Forgemasters.

“This system provides our Patternmakers with an additional tool that, through autonomous operation, will allow staff to work on complementary activities during shifts and enable production to continue outside standard working hours, improving overall efficiency and capacity. 

“The new facility will reduce costs, shorten lead times for pattern production, and in turn improve delivery times for castings.”

Ashley Roberts, pattern shop manager at Sheffield Forgemasters, added: The introduction of this new capability will broaden our patternmaking skills to include digital techniques alongside established practices. 

“The technology is already helping to develop the next generation of patternmakers.”

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