Aibuild CAM and FETS for Large-Format Additive Manufacturing

Aibuild (AI Build Limited) is a software company founded in 2015 by Daghan Cam and Michail Desyllas, former architects at Zaha Hadid Architects, with locations in London and Silicon Valley and its own R&D lab, the Ailab, in East London. It targets the trial-and-error manual processes, long build times and high failure rates that hold back large-format additive manufacturing (LFAM).

Aibuild CAM, previously known as AiSync, generates and optimises toolpaths for large-format printing of polymers and metals and is hardware-agnostic across filament and pellet extrusion, wire and powder DED, WAAM, cold spray, concrete and paste on robotic and gantry systems. It combines thermal and geometric print analysis, additive and subtractive machining in one workflow and an AI co-pilot. Aibuild FETS adds GPU-accelerated thermomechanical simulation for DED and WAAM, and Aibuild OS is an agentic AI layer that operates existing CAD, CAE and CAM tools. Users include Boeing, Ford Otosan, DLR, the UK MTC and Nikon.

• Large-format CAM: toolpath creation and automatic optimisation for polymer and metal LFAM.
• Hardware-agnostic: supports extrusion, DED, WAAM, cold spray and concrete on robots and gantries.
• Print analysis: thermal and geometric checks identify problems before a build starts.
• Hybrid machining: switches between additive and subtractive processes with automatic tool changes.
• Aibuild FETS: GPU-accelerated thermomechanical simulation validated for DED and WAAM.
• AI agent and Aibuild OS: plain-language requests drive CAD, CAE and CAM workflows for engineer approval.

Vietnamese shipyards and mechanical workshops using robotic WAAM can program and simulate large metal parts before printing. Furniture and boat makers can print large moulds and components with pellet extrusion on industrial robots. Universities and research centres building robotic printing cells can use one CAM platform across several processes.

Automated toolpath generation and print analysis replace manual programming and reduce failed builds in large-format printing. Aibuild states that FETS thermomechanical simulation runs up to 10,000 times faster than existing solutions, letting engineers predict distortion before printing metal parts. One platform covers many processes and machines, and the company reports ISO 27001 certification and SOC 2, FedRAMP and ITAR compliance for regulated customers.

Large-format additive manufacturing with robots, pellets and wire-arc processes is spreading in aerospace, automotive, marine, construction and energy for tooling, moulds and big structural parts. Software and simulation are the main barriers to repeatable results, and agentic AI is starting to automate engineering workflows. Southeast Asian shipbuilders, furniture and construction firms experimenting with robotic printing need hardware-neutral CAM tools.

Founded in 2015 in London by Daghan Cam (CEO) and Michail Desyllas (COO); operates the Ailab R&D facility in East London and has sales and support teams in Europe and North America. Awarded Best AM Software by TCT. Reports ISO 27001 certification and SOC 2, FedRAMP and ITAR compliance. Product tiers are Starter, Professional, Advanced and Enterprise, with a free trial. Launched Aibuild OS in March 2026 and Aibuild FETS in May 2026.