CEAD Flexbot 3D Printer – Engineering specialist, Sheffield Forgemasters, has launched a large-scale hybrid 3D Printer and Milling Machine to radically improve castings manufacture.
The new facility will manufacture patterns, the solid shapes which form the first critical stage of casting production. The 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 both additive and subtractive technology to be able 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.”
Ashley Roberts, Pattern Shop Manager at Sheffield Forgemasters, said: 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.”
The state-of-the-art 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 reinforce polymer materials to deliver large build volumes.
Jason Barker, Founder/CTO at CNC Robotics, which partners CEAD for UK distribution and maintenance, said: “This hybrid large‑format additive and subtractive capability isn’t just a technological upgrade, it’s a step‑change in how manufacturers like Sheffield Forgemasters can operate. By digitising and automating aspects of traditional pattern manufacturing, the CEAD Flexbot enables faster turnaround, higher repeatability, and greater design freedom.
“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.”
The 3D printer has the potential to play a key role in boosting Sheffield Forgemasters’ productivity and consistency.
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