How Graphite AM’s Jonathan Warbrick Drives Success in Industrial 3D Printing

As additive manufacturing (AM) shifts from prototype to production, service bureaus must stay agile and anticipate industry changes. Graphite Additive Manufacturing, a UK‑based AM provider, combines motorsport expertise with industrial solutions, delivering production parts, tooling, and prototypes across automotive, marine, aerospace, and defence sectors.

Graphite’s Mission

Graphite’s goal is to guide clients from prototyping to full‑scale production, selecting the optimal technology and materials for each application. What sets them apart is their in‑house material development, ensuring the highest quality and performance.

Founded in 2012 by Kevin Lambourne—formerly with Red Bull Racing—Graphite emerged to fill a gap in technical support for high‑performance motorsport projects. The company’s roots in Formula One and motorsports gave it a competitive edge, which it has since extended to broader markets.

Recent wins span automotive, marine, aerospace and defence. While motorsport remains a core focus, Graphite now serves low‑ to mid‑volume production across multiple industries.

Running a Service Bureau Today

Graphite’s growth has been steady: a 20% annual increase over the past three years, with projections of another 20‑25% this year. The firm’s success hinges on expanding from prototyping into production while balancing rapid turnaround for urgent projects with reliable, low‑to‑mid‑volume runs.

The move to production fuels growth and opens new revenue streams.

Managing short lead times in motorsport and larger production volumes in other sectors required new services: an Express line for fast turnaround and an Economy line for cost‑effective runs. To support this shift, Graphite invested in larger facilities, additional staff, and workflow automation—critical for handling lower‑value orders efficiently.

Automation streamlines scheduling and improves throughput, freeing staff to focus on quality and innovation.

Specialization remains key. By concentrating on select materials and technologies—such as HP’s Multi‑Jet Fusion (MJF), Selective Laser Sintering (SLS), and Fused Deposition Modeling (FDM)—Graphite delivers expertise and consistent quality, avoiding the pitfalls of a “jack‑of‑all‑trades” approach.

Evaluating New Technology Investments

Decisions are data‑driven. Before purchasing new equipment, Graphite tests each technology’s capabilities, limitations, and market demand. This careful vetting ensures that investments align with client needs and future trends.

For instance, the company introduced HP’s MJF over the last two years, educating clients on its performance envelope and integration into their workflows.

The State of the Additive Manufacturing Industry

While AM is still maturing, rapid advances in metal and performance plastics are closing cost gaps. High‑end automotive manufacturers, such as UK supercar makers, now use 3D‑printed under‑bonnet parts to reduce weight and enhance performance. Low‑volume production—hundreds of parts—often benefits from AM’s flexibility and speed, whereas high volumes may still favor traditional injection moulding.

There is significant potential to reduce costs with SLS and MJF, positioning them competitively against conventional methods.

Post‑processing remains a challenge; manual sanding, cleaning, and blasting consume time and labor. Automating these steps will be essential to keep AM cost‑effective at scale.

In‑House 3D Printing vs. Service Bureaus

Many companies are bringing basic AM capabilities in‑house, similar to the adoption of injection moulding. However, scaling production—especially for high volumes—requires significant investment in equipment, space, and skilled staff. Consequently, outsourcing to specialized service bureaus remains a pragmatic choice for many OEMs.

While in‑house printing offers control, the need for large fleets and expertise ensures that service bureaus will continue to play a vital role.

Developing Proprietary Materials

Graphite’s material portfolio began with carbon‑filled SLS nylon, designed to deliver maximum stiffness and strength for Formula One parts. By optimizing fiber length, the material achieves superior mechanical properties compared to standard PA12 or PA11, while presenting a natural dark grey finish that eliminates post‑processing dyeing.

Recognizing that many customers prioritize lightweight over maximum strength, the company also offers graphite‑filled SLS, which reduces cost by ~30% and retains a dark aesthetic. Current R&D efforts focus on ultra‑lightweight SLS blends to support the weight‑critical demands of hybrid and electric vehicle design.

Composite Tooling and Advanced Moulds

Graphite is active in the composite tooling market, providing soluble and extraction mandrels, ceramic SLA moulds, high‑temperature FDM materials, and jigs and fixtures. These solutions enable the shift from metal to carbon‑fiber parts in applications such as automotive, aerospace, and marine.

Industry Landscape for AM Service Bureaus

The low barrier to entry has spawned many small bureaus, but high‑quality, material‑focused providers like Graphite remain scarce. The sector is likely to see consolidation, especially in aerospace where end‑to‑end control—from powder to part—is critical for flight‑approved components.

Specialization and a robust technical footprint position Graphite well for future mergers and market leadership.

Success Stories

Graphite’s collaboration with Nifco produced a lightweight engine bracket—traditionally machined from aluminium—that demonstrates the cost and weight advantages of 3D printing. The bracket is now in production and has received positive market feedback.

FT Technologies leveraged Graphite’s materials to create durable, lightweight UAV sensors, moving from concept to market launch within nine months.

To learn more about Graphite AM, visit https://graphite-am.co.uk/.