• COST
    Consolidates equipment and workflows, reduces outsourcing costs, and saves floor space by handling additive and subtractive processes in one system.
  • TIME
    Print big and finish in-house, cut lead times, eliminate third-party finishing delays, and accelerate time to production.
  • SUSTAINABILITY
    Pellet-based extrusion significantly reduces material waste compared to traditional subtractive methods, while hybrid workflows consolidate processes to cut energy use, transportation needs and tooling waste.
  • COMPLEXITY
    Enables the creation of accurate, complex geometries and tooling within a single cell, ideal for jigs, fixtures, moulds and functional parts with demanding tolerances.

Applications

Zeus is designed for industries including aerospace and defence, automotive, construction, energy, marine and art and design. From complex moulds to finished parts, Zeus provides manufacturers with a flexible and efficient in-house solution for hybrid production.

Marine

3D printing is transforming manufacturing in the marine industry, enabling everything from tooling for glass-fibre parts to the production of entire boat hulls.

Aerospace & Defence

Discover how Rapid Fusion are revolutionising the future of the aerospace and defence industries.

Automotive

Rapid Fusion are at the forefront of 3D printing innovation for the automotive industry, enabling faster, lower-cost, on-demand part production and streamlining the automotive supply chain.

Construction

Revolutionising additive manufacturing in architecture and construction, enhancing the accuracy and efficiency of 3D-printed concrete housing.

Energy

Rapid Fusion's advanced robotic additive manufacturing solutions provide substantial advantages to energy companies, ranging from on-site repairs to automated part production.

Art & Design

When innovative art and advanced design intersect with our robotic additive manufacturing solutions, the outcomes are truly awe-inspiring.

  • TRUE HYBRID CAPABILITY
    You can print and post-process complex parts like mould inserts or custom tooling without leaving the machine.
  • TOOL CHANGER & WORKFLOW
    The EM125 Manual Tool Changer and Tool Stand let you switch between the pellet extruder and CNC tool with minimal downtime. It's designed for production flexibility, especially in low-volume or custom work.
  • SURFACE FINISH & TOLERANCE
    Zeus adds subtractive accuracy to the scale and speed of additive. Achieve smoother surfaces, tighter tolerances, and post-machined features directly no hand finishing or remounting required.

What’s in the Zeus System?

Zeus is powered by the Rapid Fusion PE320 Pellet Extruder, Epicurus Controller Pro an open-source, customisable control system, alongside a KUKA robotic arm, Modular Heated Bed, Air Plus Kit, Smart Loom Pro, and desiccant dryer and a with the CNC Milling Tool. Users can unlocking tight tolerances, improved surface finish, and wider material capability. Whether you’re prototyping, creating moulds, or producing end-use parts, Zeus delivers the flexibility and speed needed to scale.

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