{"id":714285,"date":"2026-01-23T01:47:10","date_gmt":"2026-01-23T01:47:10","guid":{"rendered":"https:\/\/www.europesays.com\/uk\/714285\/"},"modified":"2026-01-23T01:47:10","modified_gmt":"2026-01-23T01:47:10","slug":"sheffield-forgemasters-launches-hybrid-3d-printing-and-milling-system-to-transform-casting-production","status":"publish","type":"post","link":"https:\/\/www.europesays.com\/uk\/714285\/","title":{"rendered":"Sheffield Forgemasters launches hybrid 3D printing and milling system to transform casting production"},"content":{"rendered":"

Engineering specialist Sheffield Forgemasters<\/a> has launched a large-scale hybrid 3D printer and milling machine designed to significantly improve the speed, efficiency and flexibility of its castings manufacture.<\/strong><\/p>\n

The new facility will be used to produce patterns \u2013 the solid forms that create the moulds into which molten steel is poured \u2013 a critical first stage in the casting process. By combining additive manufacturing and precision milling in a single system, the technology is expected to reduce costs and lead times while improving delivery performance.<\/p>\n

At the heart of the investment is a CEAD Flexbot large-scale 3D printer, housed within a 14m x 8m x 5m enclosure. The system uses robotic arm technology to integrate 3D printing with subtractive milling, allowing Sheffield Forgemasters to produce a wide range of complex pattern geometries. Operating across two tables, one fixed and one rotating, the machine can print up to 60kg of material per hour and process fibre-reinforced polymer materials for large build volumes.<\/p>\n

Michael Howson, senior development engineer for advanced manufacturing capability at Sheffield Forgemasters, said the new system would deliver both operational and workforce benefits. \u201cThe launch of our CEAD Flexbot system will bring significant benefits to the manufacture of patterns at Sheffield Forgemasters,\u201d he said.<\/p>\n

\u201cThis 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.\u201d<\/p>\n

Ashley Roberts, pattern shop manager, said the technology would help modernise skills within the business. \u201cThe 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,\u201d he said.<\/p>\n

The system has been supplied in partnership with CNC Robotics, the UK distributor and maintenance partner for CEAD. Jason Barker, founder and CTO of CNC Robotics, said the Flexbot represented a step change for manufacturers. \u201cBy digitising and automating aspects of traditional pattern manufacturing, the CEAD Flexbot enables faster turnaround, higher repeatability, and greater design freedom,\u201d he said.<\/p>\n

He added that additive deposition also reduces material waste compared with conventional methods, supporting more sustainable manufacturing. The investment is expected to play a key role in boosting Sheffield Forgemasters\u2019 productivity, consistency and long-term manufacturing capability.<\/p>\n","protected":false},"excerpt":{"rendered":"Engineering specialist Sheffield Forgemasters has launched a large-scale hybrid 3D printer and milling machine designed to significantly improve…\n","protected":false},"author":2,"featured_media":714286,"comment_status":"","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[8817],"tags":[213742,748,22792,10443,393,4884,1302,15285,1620,22793,16,15],"class_list":{"0":"post-714285","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-sheffield","8":"tag-3dprinting","9":"tag-britain","10":"tag-businessmodels","11":"tag-digital-transformation","12":"tag-england","13":"tag-great-britain","14":"tag-innovation","15":"tag-rd","16":"tag-sheffield","17":"tag-skills","18":"tag-uk","19":"tag-united-kingdom"},"share_on_mastodon":{"url":"https:\/\/pubeurope.com\/@uk\/115941896881990847","error":""},"_links":{"self":[{"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/posts\/714285","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/comments?post=714285"}],"version-history":[{"count":0,"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/posts\/714285\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/media\/714286"}],"wp:attachment":[{"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/media?parent=714285"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/categories?post=714285"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.europesays.com\/uk\/wp-json\/wp\/v2\/tags?post=714285"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}