CCNB-INNOV has installed a Rapid Fusion ZEUS large-format additive manufacturing (LFAM) system at its Advanced Materials Centre in Caraquet, New Brunswick, Canada. The system combines pellet extrusion with a KUKA robotic platform and is designed to support prototyping, tooling, thermoplastic molds, machining, scanning, and advanced industrial applications.
The LFAM platform can process thermoplastic pellets that may be reinforced with glass or carbon fibers, expanding its suitability for composite manufacturing. Pellet extrusion also enables faster and lower-cost production than filament-based additive manufacturing for large components and near-net-shape parts.
Following the additive stage, the ZEUS system can transition to CNC subtractive machining to finish printed parts to technical tolerances. An integrated scanning capability supports the transition between additive and subtractive operations with limited operator intervention.
The technology is intended for applications including molds, tooling, prototypes, marine components, aerospace parts, and defense-related structures. INNOV says molds and master patterns can be produced within days, compared with the weeks or months typically required using conventional manufacturing approaches.
The installation also expands opportunities for dual-use manufacturing in Atlantic Canada. Recent trials at the facility have included a wood-polymer composite containing 60% wood flour, demonstrating the system’s ability to process high-bio-content composite materials.
The system currently supports parts up to about 2 meters, while a planned 20-meter linear rail is expected to enable substantially larger prints. Early marine trials have already produced a 1.9-meter boat hull, highlighting the potential for rapid production of large geometries without conventional tooling.
Source: CCNB-INNOV | LinkedIn
