Case Study – Forg3d

Client introduction

Forg3D builds the control layer for advanced metal manufacturing. From Factory Alpha in Sheffield, its ANVIL OS platform drives robotic Wire Arc Additive Manufacturing, known as WAAM, to 3D-print structural parts in titanium, inconel and steel for customers across aerospace, defence, space and fusion, including the UK Atomic Energy Authority.

Areas of R&D

Advanced welding and deposition processes
Control software for metal additive manufacturing
Materials science and process optimisation

The challenge

Forg3D needed proactive, hands-on support from an adviser who could quickly understand the technical nuances of its projects.
Their previous support had relied heavily on generic questionnaires, placing too much of the project description burden on Forg3D’s busy technical team. Important technical and legislative details had also not been fully captured, including consumables used in the robotic welding process that were directly linked to qualifying R&D activity.
Forg3D also needed support applying the newly introduced R&D Intensive Scheme rules. Correctly assessing qualifying expenditure was essential to determining whether the business met the relevant intensity threshold and could access the enhanced rate.
Despite Forg3D’s frustrations, changing adviser carried a perceived risk. The team was concerned that bringing in a new provider would create further pressure on technical staff who would need to explain the technology and projects from scratch.
Catalyst needed to get up to speed quickly while keeping the process efficient and low-burden.

Our solution

Catalyst arranged a site visit with the claim team and technical specialists to meet Forg3D’s stakeholders, see the machines first-hand and understand the development work in context.
This allowed the team to quickly grasp the control software, materials science and robotic manufacturing processes behind the claim. Because Catalyst had seen the technology first-hand, Forg3D did not have to write lengthy explanations, reducing onboarding lag.
A dedicated project manager kept the process moving, ensuring timescales were met while minimising the burden on Richard and the wider Forg3D team during a busy fundraising period.

The result

With a stronger understanding of Forg3D’s projects and technical challenges, Catalyst reviewed the cost base in detail and identified qualifying activity and costs that had not previously been considered.
This included reassessing consumables used in the robotic welding process and ensuring they were included in the context of Forg3D’s qualifying R&D activity.
Through a detailed understanding of the activities and cost base, Catalyst concluded that R&D expenditure was over 30% of total spend. This meant Forg3D qualified for the Enhanced R&D Intensive Scheme and could access a more generous benefit rate.

Client quote

Having someone sitting there and actually saying, ‘Don’t worry about that, I’ll take care of this. I’ll take all of the new work on the plate, just answer these questions’ was a massive plus for us. Instead of our engineers spending their time on the claim process, they could focus on what they do best – developing cutting-edge technology.
Richard Mincher
Founder, Forg3d