Breton has introduced Genesi, a breakthrough hybrid manufacturing platform that merges large format fused deposition modelling (FDM) with high-speed CNC milling, delivering a paradigm shift in mould and pattern production. By combining additive printing and subtractive milling in a single system, Breton Genesi enables the direct creation of complex, monolithic moulds with unprecedented efficiency and precision.

The Genesi system is modular, capable of producing parts up to 30m long, 5m wide, and 2.5m tall, with reinforced thermoplastics extruded at rates up to 200 kg/h. The hybrid approach reduces lead-times, cuts costs, and eliminates the need for multiple processing stages, while also enabling aerospace-grade surface finishes through integrated milling, sanding, and polishing.

At the core of Genesi is Breton CANOVA software, powered by artificial intelligence and machine learning. CANOVA automates process optimisation with predictive and adaptive controls, material databases with pre-tested recipes, real-time thermal monitoring via infrared cameras, and a simplified user interface. This intelligent ecosystem ensures error reduction, superior part quality, and streamlined workflows from prototyping to production.

Key benefits include:

1. Lead-time and cost optimisation Integrated additive and subtractive workflow accelerate prototyping and production.
2. Superior quality and precision Aerospace-level tolerances with improved surface finish.
3. Design freedom and flexibility Large-format, monolithic geometries unlock new design possibilities.
4. Sustainability Reduced waste and support for recycled technical materials such as PETG, ABS, Ultem, and polycarbonate.
5. AI-driven process control Predictive software ensures consistent quality and material versatility.

Breton Genesi brings the concept of a factory within the factory , offering industries from aerospace and automotive to marine, energy, and tooling a compelling solution for rapid prototyping, customised small-batch production, and sustainable large-scale tooling.

Source: breton.it