The JCB Academy is proud to celebrate the outstanding achievements of former Sixth Form learner Musa, who has won the Bronze medal in the Additive Manufacturing category at the WorldSkills UK National Finals 2025 in Swansea.
This year’s competition attracted just under 8,000 applicants, with only 417 finalists invited to compete across all categories. In Additive Manufacturing, only seven learners nationwide secured a place in the UK final. To earn a Bronze medal in such a competitive field is an exceptional accomplishment, reflecting Musa’s technical skill, precision, and ability to perform under pressure.
Musa completed his studies at The JCB Academy Sixth Form, progressing onto the highly prestigious Nuclear Submarine Apprenticeship at Rolls-Royce, one of the most sought-after engineering programmes in the country. His achievement demonstrates the strength of our specialist engineering curriculum, the industry-focused pathways at our Sixth Form, and the high expectations we set for every learner.
DAY 1 TASKS
1. Batch Production (5% of overall marks)
Finalists were given a technical drawing that had to be exported to a 3D printer. They were required to:
- Configure the printer
- Optimise setup and layout
- Produce as many accurate keyrings as possible
- Balance timing against other tasks
Competitors had to decide strategically whether this task was worth the time investment or whether focusing on other areas would earn more marks overall.
2. 3D Scanning and Reverse Engineering
Learners completed a one-hour 3D scanning task involving a turbine component:
- Scan the turbine and ensure correct alignment between layers
- Generate a 3D CAD model
- Identify faults in the original component
- Redesign the turbine to eliminate issues
This tested precision, design thinking, and the ability to analyse engineering defects effectively.
3. Design for Manufacture (DFM) Redesign Task
Competitors received a table model with intentional faults. They were required to:
- Use up to six 3D prints as test pieces
- Configure printers correctly (orientation, supports, layer settings, etc.)
- Redesign the table to withstand specific load conditions
- Improve the design without over-engineering
This task assessed practical prototyping skill, iterative design, and applied engineering judgement.
DAY 2 TASKS
1. Batch Production Continuation
Learners continued printing as many accurate keyrings as possible, ensuring each item met quality standards without faults.
2. Design and Make: Broom Holder Mechanism
Using an existing wall plate, learners designed and manufactured:
- A new attachment
- A mechanism capable of securely gripping a broom handle
- A functional and reliable prototype
This required precise measurement, tolerance control, and functional design.
3. Air Suction Pad Challenge
Competitors had to design and create:
- A suction pad capable of lifting a solid block
- A solution with enough surface area and airtight integrity
- A secure connector so that the air line could not detach
A high-level understanding of pressure, surface contact, and material properties was essential.
4. Site Service Plug Adaptor
Learners engineered a safety product designed to attach to an existing 110V power adaptor. They had to:
- Create a retrofit solution enabling pins to be removed safely
- Produce a tool to assist with pin removal
- Ensure the adaptor head design was functional, ergonomic, and manufacturable
This required problem-solving, practical design skills, and a focus on user safety.
A Remarkable Achievement: Musa Wins Bronze
After two intense days of engineering challenges, technical assessments, and continuous scrutiny, Musa secured the Bronze medal in the Additive Manufacturing category.
This is an exceptional accomplishment, especially considering:
- Over 80 learners entered the competition
- Only 7 made it to the UK finals
- Additive Manufacturing is one of the fastest-growing, most technically demanding engineering fields
Musa demonstrated outstanding competence in CAD, practical engineering, and 3D printing, as well as the resilience required to tackle unfamiliar tasks under timed conditions.
Proudly Developing the Engineers of the Future
This competition reflects the academy’s commitment to our motto:
Changing lives by developing the engineers and business leaders of the future.
We are immensely proud of Musa’s achievements and the dedication shown by all learners who take on national-level challenges such as WorldSkills UK.
