In the ever-evolving world of manufacturing, the implementation of 3D printing technology has introduced a wave of innovation. This technology is particularly suitable at automating the manufacturing processes that traditionally required painstaking, intensive hours of manual labor. Operators have found innovative ways to integrate large format additive manufacturing (LFAM), replacing not just one, but several steps in the part production process. The opportunities for applications for LFAM technology are endless, with countless ways to introduce this technology in a production process. Rapid Prototyping, a Hungarian large-format prototype manufacturing company, owned by Foarboc Ltd. with over 20 years of experience, is a perfect example. They use LFAM technology to produce multiple parts and tooling, showcasing the versatility and efficiency of this technology in modern manufacturing.
In 2020, Rapid Prototyping was amongst one of the first customers to acquire CEADs standalone pellet extruder. Already in possession of several CNC-axis machines, the E25 robot extruder was integrated with their Big Blue, a 4850 x 2635 x 1460 gantry machine. With their CNC-machine now transformed into a large format 3D printer, they started manufacturing for the yacht industry, maritime industry, custom trucks manufacturers, and other related industries. Moving from the use of CNC machined polyurethane foam and hand layup glass fiber-reinforced plastic (GRP) to 3D printing molds using 30% short glass fiber-reinforced polypropylene, György Juhász, owner of Rapid Prototyping and Foarboc Ltd (Budapest, Hungary), cut back their labor time by up to 50%.
Now, 4 years later, Gyorgy has seamlessly integrated 3D printing into his production process, mainly focusing on manufacturing plugs for boat hulls and molds for parts of professional and pleasure crafts.

CNC milling a 3D-printed block. Photo credit: Foarboc Ltd.
DECREASING THIRD PARTY DEPENDENCY AND OVERALL LEAD TIMES
Since the introduction of LFAM into the production process, the overall lead times at Rapid Prototyping have been notably reduced. Prior to this, they produced plugs by milling foam blocks to the correct shape. The procurement of these blocks relied on an external supplier which often caused delays in generating client offers. Waiting for quotations and facing potential stock shortages at the supplier, typically led to a minimum two-week lead time for foam block delivery only.
Occasionally, the team even had to construct larger blocks from the ones they received, due to the supplier’s lack of the required size, before they could start the milling process. Now, they have recycled pellet material in stock, as we will describe below, allowing them to start a print at any time in the desired size. Production can potentially start the day after receiving a new request, significantly expediting the overall workflow.
The world has experienced that supply chains are tremendously susceptible to global disruptions, underscoring the urgent need for resilient strategies and adaptable frameworks in the face of unforeseen challenges. Rapid Prototyping is a great example of building more resilient supply chains by localizing production, by using LFAM to enable on-demand production without relying on large inventories.

CAD drawing of a boat plug divided in 3D-printed blocks. Photo credit: Foarboc Ltd.
The team has optimized the manufacturing workflow. The easiest and fastest way of creating a plug is dividing the entire plug into blocks and printing them per piece on their Big Blue with CEAD extruder. “We mill a baseline and reference points before moving it to another CNC machine for the final finish, while the Big Blue starts a new print.” György explains. Since there are 5 CNC machines of different sizes at his disposal, moving the printed block to another machine is the most efficient method for his team to clear the 3D printer quickly for another round of printing. This way, they print new parts every day. In cases where MDF blocks were typically used, 3D printed blocks are also lighter and easier to handle, introducing them in the production process is therefore speeding up the plug assembly process.

Fully assembled boat plug. Photo credit: Como Yacht Ltd.
CUTTING BACK ON MANUAL LABOUR
In 2022, a team of 3 people including himself, manufactured a plug for a 55-feet boat hull consisting of 44 pieces, a project during which they processed 5000 kg of recycled PETG in 12 weeks. “Before, we would have needed 9 people working around the clock to produce the blocks for the plug.
Now, I only need additional workforce when it’s time to begin assembling the plug”. Moreover, finding skilled labor for plug part production has become increasingly challenging, which is why automation facilitated by 3D printing provides an additional benefit. While the machines are operating, his team gets to spend their time on other activities, thus experiencing more efficient division of tasks.
SUPERIOR END-PRODUCTS
Implementing 3D printing also created new material opportunities. It enabled György to seamlessly transition from using polyurethane foam to a sturdier thermoplastic material. “Foam is influenced a lot by cold and warm weather, expanding and shrinking under different circumstances.
This leads to more inaccuracies when using the foam plug to create the fiber-glass mold, which are difficult to compensate and require more layers of fiberglass to prevent these inaccuracies from affecting the final part.” György explains. The use of 3D-printed plugs ultimately leads to a superior end-product, while requiring fewer layers of fiberglass (if at all needed) and paint compared to traditionally manufactured plugs using foam. Again, resulting in the additional benefit of speeding up the creation of the plug.
Besides using 3D printing technology to create new boat plugs, they also print molds. They are currently manufacturing a deck of a 35-feet boat, of which 50% is manufactured using 3D-printed molds. With printing, it is easier to make quick design iterations and to create custom-made boats or elements, a trait that is appreciated by the maritime industry.

Fiberglass mold for yacht. Photo credit: Como Yacht Ltd.
REDUCING MATERIAL WASTE WITH 3D PRINTING AND RECYCLING
Apart from the numerous advantages it offers, the primary motivations for György and his team to transition to 3D printing was the environmentally friendly nature of this technology. 3D printing technology perfectly lends itself to the usage of recycled materials, such as PETG. But for the team, the enormous amount of material wasted when using conventional manufacturing technology was a turning point.
“More than 50% of material was going to waste by milling the foam blocks into shape, without the possibility to recycle any of it.” By 3D-printing blocks to near-net shape, the amount of waste is reduced significantly. The team is taking it a step further by making optimal use of the recyclable character of thermoplastics. After usage, the entire plug for the 55-feet hull that they printed 3 years ago, was shredded and utilized for a new project: they are now printing a 28-feet boat plug with the same recycled material.
In addition to this, the company also powers its machines with solar energy, reinforcing its dedication to environmentally responsible manufacturing. This demonstrates that it is possible to start manufacturing in a more sustainable fashion, integrating the principles of circular economy in the maritime industry, an important topic in today’s world.
Wondering how CEAD technology can help you stay ahead in the maritime industry while promoting sustainable manufacturing, enhancing efficiency and reducing costs? Contact CEAD’s sales team (sales@ceadgroup.com) today to discover how LFAM solutions can transform your operations.