UK-based Rapid Fusion, a specialist in turnkey 3D printing solutions, has teamed up with Italian start-up Nanoo to redefine concrete mould manufacturing. Using its advanced ZEUS 3D robotic system, Rapid Fusion created complex moulds for Nanoo, enabling the production of table legs for a high-end Italian furniture manufacturer. This project highlights how additive manufacturing can dramatically reduce production times and costs while enhancing sustainability.
The moulds, traditionally taking up to two weeks to produce, were completed in just a few days thanks to the ZEUS system. By combining 3D printing with an integrated CNC milling tool, the collaboration achieved precision quality while minimizing labor costs and leveraging recycled PET-G materials to bolster environmental performance.
This groundbreaking contract provides a test case for the construction sector, showcasing the potential of 3D printing for creating bespoke moulds used in large-scale projects, free-form facade elements, and architect-designed furniture. Trials demonstrated that advanced cementitious materials like UHPCs, when paired with PET-G moulds, maintain exceptional accuracy and performance. Current testing aims to validate the reusability of the moulds, with expectations exceeding 100 uses without maintenance.
“Construction is an industry facing increased pressure to innovate, optimise costs and reduce environmental impact…switching to additive manufacturing for some of its moulds helps them deliver on these objectives,” said Martin Wood, Director of Sales at Rapid Fusion. He emphasized the significant waste reduction achieved compared to composite moulds, which often generate excess material and environmental degradation when discarded.
Rapid Fusion, a sister company to EVO 3D, has solidified its position as a leader in additive manufacturing platforms designed and built in the UK. The company’s ZEUS system, which includes CNC milling for precision post-processing, is already making waves in sectors like automotive, aerospace, medical, and renewables. Nanoo has been so impressed with the technology that it has signed on to be among the first to deploy ZEUS.
“This is an interesting partnership that is working because we are playing to each other’s technical strengths in exploring how we can design and manufacture concrete moulds using large-format 3D printing,” said Mirko Scaburri, founder of Nanoo. He added, “The additional design geometries made possible with additive manufacturing are a big sell for architects and construction companies.”
As both companies continue pushing boundaries, the partnership underscores how 3D printing can transform construction with faster, more sustainable, and cost-effective solutions.
