British engineering group Sheffield Forgemasters Intl. Ltd. has added a large-scale, hybrid 3D printer and milling machine to improve its metalcasting operations. The new system will manufacture patterns needed to produce sand and resin molds for casting steel components, with potential to increase productivity and consistency, according to 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,” commented Michael Howson, senior development engineer. “The new facility will reduce costs, shorten lead times for pattern production, and in turn improve delivery times for castings.”
Sheffield Forgemasters produces some of the world’s largest steel castings, for defense, nuclear power, offshore energy, construction projects, as well as heavy industrial systems. It can melt and pour up to 600 metric tons (660 short tons) of molten steel for finished components weighing up to 350 tons (386 short tons.)
The company also produces large-dimension steel forgings. Its roots reach back more than 250 years, and since 2021 it has been a holding of the U.K. Ministry of Defence, a transition taken to solidify the country’s defense manufacturing base.
CEAD is a Netherlands-based developer of large-format additive manufacturing systems integrated with subtractive processes and automation provided as turnkey installations. The CEAD Flexbot 3D printer is a large-scale system, housed in a 14x8x5-m enclosure, served by a robotic arm technology. The system combines 3D printing and milling (additive and subtractive technologies) to create a range of complex patterns. It incorporates CEAD pellet-extrusion technology, a Comau robot, Siemens Sinumerik One control technology, a modular worktable (standard size 1.2x1.8 meters), the safety enclosure, and a dryer.
According to pattern-shop manager Ashley Roberts, the new capability provided by the AM system will broaden Sheffield’s patternmaking skills, to include digital techniques alongside established practices. “The technology is already helping to develop the next generation of patternmakers,” Roberts stated.
The machine operates across two work tables, one fixed and one rotating. It can print up to 60 kg (132.3 lbs.) of material per hour, and can use various fiber-reinforced polymer materials for large build volumes.
Jason Barker, founder/CTO at CNC Robotics, which partners CEAD for U.K. distribution and maintenance, stated: “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 digitizing 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.”