Rapid Fusion has announced a major breakthrough in 3D printing with the launch of its new industrial-scale machine, Medusa. The unveiling took place at the company’s advanced research and development centre in Exeter and was attended by over 100 industry experts, potential customers, and investors.
The innovative system, funded in part by a £1.2 million Innovate UK grant, is the first of its kind developed in the UK. The company claims that Medusa is three times faster than conventional 3D printers, twice as accurate, and can reduce training and maintenance costs by up to 30%.
During the event, guests witnessed a live demonstration of the machine printing a complex construction mould in less than five hours. The printer, which features a build volume of 1.2 cubic meters and reaches movement speeds of 1,200mm per second, showcased its capabilities in real-time.
Attendees also heard from key project partners, including Guy Brown of AiBuild, Dickon Walker from the National Manufacturing Institute Scotland (NMIS), Chaco Van Der Sijp of Innovate UK, and Ravi Toor from Filamentive. Each speaker highlighted the printer’s unique features and discussed the potential impact of the technology on the UK’s manufacturing landscape.
Jake Hand, Managing Director of Rapid Fusion, described the launch as a milestone achievement.
“It was a fitting launch event for Medusa, the result of 18 months of intense development and innovation,” said Hand. “Led by Martin Jewell and supported by our partners, we have delivered something truly unique — not just in the UK, but potentially worldwide.”
Hand added that the initial response from visitors was overwhelmingly positive. Several discussions are already underway with potential buyers, paving the way for scaled-up production.
Paul Rowe of Applied Automation (UK) Ltd also praised the project.
“It was a fantastic morning,” Rowe said. “Medusa is the first large-format 3D printer built in the UK, and the team at Rapid Fusion is redefining the future of large-format additive manufacturing. We’re thrilled to support them as they move into full production.”
Developed with support from Rolls-Royce, AiBuild, and NMIS, the gantry-style printer integrates multiple technologies — including a pellet extruder, filament extruder, and CNC machine tool — into one system. This single-source solution is designed for producing large moulds and tooling components across industries such as aerospace, marine, automotive, and construction.
The printer uses advanced artificial intelligence to improve efficiency and precision. Priced at around £500,000, Medusa has already attracted strong interest from Tier One suppliers and major manufacturers. Rapid Fusion projects that first-year sales could generate as much as £5 million in revenue.
With the launch of Medusa, Rapid Fusion is positioning itself as a leader in high-performance additive manufacturing, with plans to grow further as demand increases for advanced, large-scale 3D printing solutions.
