Acknowledged for its heavy engineering and steel casting/forging expertise, Sheffield Forgemasters recently debuted in the additive manufacturing industry with the installation of a hybrid 3D printer.
The launch comes along with a milling machine to improve casting manufacture.
The company’s own description of the launch positions the hybrid system as a new digital manufacturing capability that broadens their patternmaking skills and introduces digital techniques alongside traditional practices, a clear sign that this is a strategic expansion into additive approaches.
The new process
The new facility will manufacture patterns; the solid shapes which form the first critical stage of casting production. Patterns are used to make a sand and resin mould which liquid steel is poured into to create the casting.
The CEAD Flexbot 3D printer is a large-scale system, housed in a 14m x 8m x 5m enclosure. Robotic arm technology combined with 3D printing and milling uses additive and subtractive technologies to create a wide range of complex patterns.
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.”
The machine operates across two tables, one fixed and one rotating, can print up to 60kg of material per hour, and can use a range of fibre reinforced polymer materials to deliver large build volumes.
“The system also supports more sustainable manufacturing. Additive deposition reduces waste material compared to conventional subtractive-only workflows, and the ability to recycle polymer feedstocks further strengthens the environmental benefits. We’re excited to partner with Sheffield Forgemasters as they harness this technology to enhance capability, grow skills, and future-proof their patternmaking operations for decades to come,” Jason Barker, Founder/CTO at CNC Robotics, which partners with CEAD for UK distribution and maintenance.
The 3D printer has the potential to play a key role in boosting Sheffield Forgemasters’ productivity and consistency.
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