Additive Layer Manufacturing

“The unique capabilities of additive layer manufacturing technologies enable new opportunities for pushing design boundaries and customisation, very significant improvements in product performance, multi-functionality, and lower overall manufacturing costs”

Dan Fleetcroft, Engineering Design Director

Additive Layer Manufacturing (ALM)

The PES Performance team, based at the Advanced Manufacturing Park (AMP), Sheffield has experience of designing with ALM. This is within the design process as a material and as a solution & application in other engineering design projects.

Design for manufacturing (DFM) has typically meant that designers should tailor their designs to eliminate manufacturing difficulties and minimise costs. However, the improvement of rapid prototyping (RP), or Additive Layer Manufacturing (ALM), technologies provide an opportunity to re-think DFM to take advantage of the unique capabilities of this technology.

Due to the advances of additive manufacture (ALM) technologies, it is now being commonly used as a final solution for small batch manufacture and not just for models or prototype evaluation. These technologies and processes are now being used in multiple sectors including medical, aerospace and fabricated moulds to name but a few.


Capabilities of Additive Layer Manufacturing

The unique capabilities of Additive Layer Manufacturing include:

  • Shape complexity: it is possible to build virtually any shape; lot sizes of one are practical; customised geometries are achieved readily, and shape optimisation is enabled.
  • Material complexity: material can be processed in one point, or one layer, at a time, enabling the manufacture of parts with complex material compositions and designed property gradients. It should be noted new materials are being developed almost on a weekly basis.

We consider all projects regardless of size or complexity and 70% of our clients are internationally based. Whether a quick turnaround, simple tooling or modelling job, or complex design engineering projects, we will be able to deliver you a solution.

If you would like to discuss your project and how our solutions can help you, then please call us for a chat at +44 (0) 114 321 6375 or email with your enquiry. 



The team have provided solutions for UAV composite propellers, the F-35 (Joint Strike Fighter) project, and reverse engineering projects, with our blue light scanning service.

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