A major new deal in the UK manufacturing sector is set to bring a groundbreaking 3D printer to market. Rapid Fusion, a leader in robotic additive manufacturing (AM) systems, has partnered with Applied Automation in a move that will see the Medusa printer move from prototype to full-scale production.
The Medusa, a large-format hybrid 3D printer developed in the UK, is expected to enter the market in early 2026. The two companies, both based in the South West of England, are expanding a two-year collaboration to bring this innovative product to life.
Engineering teams from Rapid Fusion and Applied Automation will work together to prepare Medusa for commercial use. The printer has already attracted strong interest from companies in sectors such as aerospace, automotive, construction, medical, and renewable energy.
The first steps will include design for manufacture (DfM) and supply chain setup. Applied Automation will also build a dedicated assembly and testing facility at its site in Plymouth to support the project timeline. The venture is expected to generate over £5 million in revenue in its first year and create up to 10 new jobs across the two firms.
Martin Jewell, Chief Technical Officer at Rapid Fusion, said: “We’re excellent at innovation and product development, but we’re not equipped to manufacture in low to medium volumes. That’s where Applied Automation becomes a vital partner. We’ve already developed Apollo and Zeus, our earlier robotic systems, with them. It made perfect sense to have them manufacture Medusa too.”
He added that a key goal is to reduce early production costs. The aim is to streamline DfM and create an assembly line capable of building each Medusa unit in just six weeks.
“This gives us a great chance to be first to market and have machines in use by March 2026,” he said.
Supported by a £1.2 million Innovate UK grant, Medusa offers impressive advantages. It is three times faster and twice as accurate as traditional 3D printers. It also cuts training and maintenance costs by around 30%.
The gantry-style printer combines pellet extrusion, filament printing, and CNC machining into one machine. This makes it ideal for creating large moulds and tooling, especially in industries like aerospace, automotive, marine, and construction. It includes advanced AI features and Siemens motion control, has a build volume of 1.2 cubic metres, and moves at speeds up to 1,200mm per second.
Paul Rowe, Director at Applied Automation, said: “Our role is to take Rapid Fusion’s exciting technology and make it scalable for the market — both in cost and speed. Our Plymouth site has all the tools, with over 200 specialists in control systems, tooling, and manufacturing working together.”
He explained that Applied Automation will handle most of the assembly and testing. The plan is to produce two pre-production models in the next few months, then launch full-scale commercial production in early 2026.
“Compliance is key. By handling the build, we ensure Medusa meets CE marking and UL508a standards — the latter is crucial for entering the North American market,” Rowe added.
Jake Hand, Managing Director of Rapid Fusion, said the launch marks a major milestone for UK manufacturing.
“This is the first industrial 3D printer of its size and speed to be made in the UK. We’re proud to keep production local, especially here in the South West. Applied Automation is a world-class partner and will help us hit our target of £5 million in first-year sales.”
He also confirmed that new global reseller agreements are now in place, which could help boost revenue growth even faster. “This is just the beginning,” Hand said.
