Kendal-based motorcycle exhaust manufacturer Fuel Exhausts is embracing cutting-edge 3D technology to revolutionize its design and production processes. With £30,000 in matched funding from the Made Smarter Adoption Programme, the company has acquired a 3D scanner, CAD software, and a 3D printer—creating an integrated digital design system that slashes prototyping time by 93%.
From Virtual Testing to Physical Products
The new technology enables Fuel Exhausts to design and test products in virtual environments before physical production begins. The 3D scanner introduces reverse engineering capabilities, allowing the company to digitally capture existing motorcycle parts and create compatible components. “This transforms our ability to develop prototypes in-house and expand into new product lines,” said co-owner Damian Turner.
Efficiency Gains Drive Business Growth
Beyond faster prototyping, the digital system delivers multiple operational benefits: reduced material waste, lower production costs, and increased profitability. The investment will also create two new production jobs as the company expands its capabilities. Turner emphasized that the technology aligns with their commitment to quality, noting it helps maintain their reputation for exceptional customer service while modernizing manufacturing processes.
Made Smarter Powers SME Innovation
Made Smarter’s North West Adoption Programme Director Donna Edwards praised Fuel Exhausts as a model for small manufacturers embracing digital transformation. The government-backed initiative provides technology advice, workshops, and funding to help regional manufacturers compete globally. “This demonstrates how digital tools can fundamentally change product development,” Edwards said, encouraging other SMEs to explore similar opportunities.
Future-Proofing British Manufacturing
The investment positions Fuel Exhausts to develop complementary motorcycle accessories alongside its core exhaust products. By bringing prototyping in-house, the company gains agility to respond to market demands while reducing reliance on external suppliers—a strategic advantage in the competitive motorcycle aftermarket sector. This move exemplifies how targeted technology adoption can help traditional manufacturers innovate while preserving their artisanal quality standards.
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