Chris Fulton, managing director of SYS Systems, believes the versatility of 3D printing is only now being realised and explains why your ‘additive’ machine tool could well be the most profitable item on your shopfloor.
SYS Systems, which is part of Carfulan Group, has seen a major increase in the number of sub-contract precision engineers embracing the Stratasys Fortus 900 FDM 3D printer for producing additive manufactured parts to the world’s biggest OEMs.
In fact engineers across automotive, aerospace and defence are now switching on to the fact they can use this technology, which is unmanned and can run 24/7, to produce components that offer a far greater margin than your traditional CNC milled or turned part. The F900’s dynamic performance, large bed chamber (9.14.4 x 609.6 x 914.4mm build envelope) and versatility means it is just as efficient manufacturing one large part or a full tray of precision parts.
“In essence, this solution has become the machine tool you didn’t think you needed and the one that is the most profitable on your shopfloor,” explained Chris Fulton. “It is capable of prototyping large parts in a single print (avoiding high cost and lead times) and can replace heavy metal jigs, fixtures and manufacturing aids with lighter tools made from strong, durable thermoplastics.
“Importantly, being a high-end industrial printer means it prints in materials that are certified by the big OEMs, such as Rolls-Royce.”
Using the F900, SYS Systems clients are regularly meeting product goals faster, especially for end-use parts for low volume orders, obsolete parts or as a bridge to full production.
The 3D printer is also engineered to help subcontract specialists move towards a ‘Smart Factory’, embracing the industry 4.0 concepts of automation, on-demand manufacturing and data.
Greater Adoption
The way additive manufacturing is viewed has changed beyond all recognition with this form of production now seen as being more versatile and capable of low to medium volumes. Not bad for what previously used to be regarded as simply a prototyping tool.
Adoption in different sectors has also accelerated. We now see 3D printing used in every sector imaginable, whether that is for components for Formula 1, safety critical parts for next generation aircraft or applications within energy generation.
“Dental is one of our biggest growth markets at the moment. We’re helping laboratories, surgeries and dentists achieve some massive commercial gains from using Stratasys technology,” pointed out Fulton.
One example is Bant Dental, who has embraced additive manufacturing to accelerate its move to a state-of-the-art facility in Macclesfield.
Founded by husband-and-wife team Steve and Susan Bant in 1990, the company has enjoyed a major surge in business after switching from analogue to digital technology, tapping into the capabilities of the industry-leading Stratasys J5 DentaJet. The 3D printer allows the lab to print fully customisable, full-colour monolithic dental parts, including dentures, surgical guides and models. Multiple components can be printed in a single run, with dentures produced with realistic depth and translucency, removing labour-intensive steps and reducing potential errors.
“When I started back in 1990, everything was analogue based. However, as time went on, digital started to creep in and, as it stands today, we are 95% digital at our new lab on Beech Lane in Macclesfield,” explained Steve Bant.
“Initially, the J5 DentaJet could produce models, implant models, guides and special trays and this made us a lot more efficient as a business. Then SYS Systems received approval of its groundbreaking TrueDent CE-marked resin in the UK, and this opened up a whole new range of possibilities, including 3D printing full-colour monolithic dentures.”
He continued: “The ability to print in colour is next level. You can alter the colour of the gingiva, you can give it depth, and you can add translucency on the tips of the teeth. They’ve actually got real depth and, importantly, look fantastic!”
SYS Systems has been a trusted partner throughout Bant Dental’s digital journey. From initial introduction to the available solutions, its 3D printing experts have provided expert guidance and technical assistance to Steve and his team, ensuring the lab gets the most from its investment in Stratasys technology.
“The speed and the accuracy of the J5 DentaJet is simply next level and has revolutionised our workflow,” continued Dan Bant, Digital Lab manager and son of Steve and Susan.
“In the simplest terms, the volume of work we produce digitally today would necessitate the need for at least three times the number of staff we currently have. The investment we’ve freed up has been poured back into making Macclesfield one of the most advanced dental labs in the country.”
J55 Prime
Making the Most of MACH 2026
Carfulan Group is using MACH 2026 to showcase the latest additive manufacturing technologies, and this year will be no different with three of its best performing machines on display.
The Fortus F450 will be one of the stars of the event, a multi-application manufacturing solution that reduces design and build times, optimises manufacturing workflows and supports factory innovation.
It will be joined on Stand 20-230 by the desktop J55 Prime (ideal for fast concept and high-fidelity models) and Origin 2. Powered by a new 5K DLP projector, the latter delivers the highest accuracy and smoothest surface finish of all resign technologies and one that is comparable to injection moulding.
Fulton concluded: “2026 is going to be an exciting year for our business. We have just been named as the ‘Number 1 Partner Status’ for Stratasys across Europe, Middle East and Africa (EMEA), which is a big, big honour.
“With new technology on the way and a really strong order book, we’re hoping to post our best ever twelve months for additive manufacturing.”
Learn more www.sys-uk.com
For more AM/3D printing stories, visit: https://designsolutionsmag.co.uk/category/additive-manufacturing-3d-printing/
This story first appeared in the February issue of Design Solutions.
