Nexus Additive: Unlocking the promise of metal 3D printing with AI-QA

Founder: Dr Sebastian Larsen, Co-founder and CTO (Postdoctoral Researcher, Imperial College London)

Metal 3D printing, or additive manufacturing, is a transformative technology, allowing for the creation of complex, high-performance components in sectors from aerospace to medicine. However, the process is not without its challenges. Inherent variations can lead to costly and time-consuming quality assurance checks after production. 

Nexus Additive, a venture co-founded by Imperial postdoctoral researcher Dr Sebastian Larsen, has developed an AI-powered solution to solve this problem in real time. The idea for Nexus Additive emerged during Sebastian’s PhD studies, where he, along with his co-founders, identified a clear commercial application for his research. 

As metal 3D components are printed layer by layer, vast quantities of sensor data are captured from cameras and photodiodes. Simply handling and interpreting this information, which can exceed a terabyte per part, is a major challenge for industry.Turning the data into actionable insights was a real challenge requiring months of in-depth analysis. To scale this technology for industry, tools were needed that didn’t require PhD-level expertise to interpret.

Nexus Additive’s solution is an intelligent quality assurance platform. During metal 3D printing  sensor data is fed into an AI model that can instantly detect defects and anomalies that might otherwise be missed or only found much later in post-production. This saves significant time and money, increases machine utilisation, and ultimately, as Sebastian puts it, “unlocks the full possibilities of metal 3D printing.”

The company has already demonstrated that its technology is applicable across machines from different manufacturers and has received multiple expressions of interest. With a team that has grown to eight people, Nexus Additive is preparing for its next phase of growth. The company is currently in the process of securing collaborative grants with UK aerospace primes to demonstrate how its technology can optimise aircraft components and help reduce emissions.

Having raised £1.12 million in initial investment, as well as receiving a grant in partnership with OSSTEC Ltd (which makes 3D-printed knee implants), Nexus is now well-capitalised to achieve its ambitious goals for the coming year: acquiring its first customers and releasing its product to the market.

Sebastian found the AI SuperConnector (AISC) programme invaluable in preparing the venture for this stage. He highlights the regular feedback from pitch events, AI-specific masterclasses, and networking opportunities that led to investor meetings. He even credits the programme with helping him improve his public speaking skills through coaching with the Royal College of Music. Through the support of AISC, Nexus Additive is now poised to bring a new level of confidence and efficiency to the world of advanced manufacturing.