British manufacturer Rapid Fusion has unveiled “Bob,” an AI-powered assistant designed to optimize the operation of its large-format 3D printing systems. The solution is aimed at industries with complex manufacturing requirements such as aerospace, automotive, construction, medical technology, and defense.
The system took eight months to develop and involved extensive testing. Bob (“Base of Build”) is designed to give users simplified control of the printers, reduce downtime through preventive maintenance, and make it easier to get started. The assistant is based on an extensive knowledge database that can be used both online and in isolated, security-critical environments. Rapid Fusion is thus also addressing customers who have to comply with strict intellectual property protection requirements.
The system is compatible with existing models such as Apollo and Zeus, as well as with the latest Medusa machine. Medusa is considered the first large-format hybrid gantry 3D printer developed in the UK. According to the company, the AI takes over 1,000 printing parameters into account and provides optimized presets for more than 100 different components. These include features such as “Smart Extrusion Readiness,” which monitors temperature stability in multiple heating zones and provides automated approvals for the printing process.
Particularly noteworthy is the material-related intelligence. Bob can incorporate properties of high-temperature polymers and composite materials by taking into account parameters such as heat deflection temperature, shrinkage, or expansion behavior. Natural language control allows queries such as “print high-temperature-resistant tool” to be translated directly into suitable configurations.
In addition, the assistant offers multi-level task control. Simple commands are executed via pattern recognition, while more complex requirements access comprehensive material databases and context-related analyses. Smart Chained functions are also integrated. Multiple commands can be combined automatically, such as the selection of materials, temperature profiles, and post-processing steps.
Rapid Fusion plans two levels of use: an advanced version for partners and research institutions, and a standard version for existing customers starting in 2026. Updates will be available via remote access.