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CNC Machining · Composites · Additive Mfg · Prototyping
When traditional manufacturing hits its limits, Sykes delivers.
We help teams bring complex ideas to life — faster, locally, and at scale — using large-format 3D printing, precision CNC machining and deep composite expertise to deliver complex parts without the cost, delays and constraints of traditional manufacturing.
Sykes Advanced Manufacturing (SAM) is the advanced manufacturing division of Jeff Sykes & Associates — built to help industry deliver complex components faster, more efficiently, and without the constraints of traditional manufacturing.
Backed by nearly 60 years of composite manufacturing expertise, SAM combines large-format 3D printing, precision CNC machining and proven composite production to deliver end-to-end solutions — from concept and design through to full-scale manufacturing.
What began as an internal capability to support high-performance composite production — including tooling for world championship and Olympic-winning programs — has evolved into a fully integrated manufacturing platform supporting customers across marine, aerospace, infrastructure, housing and defence.
Operating from a 5,000m² primary facility with dedicated secondary manufacturing and R&D spaces, Sykes offers a seamless workflow across CAD/CAM design, large-scale additive manufacturing, CNC machining, composite tooling and production, finishing, and final delivery.
The result is a single manufacturing partner capable of reducing tooling cost, compressing lead times, and delivering complex, large-scale components with confidence.
Composite structures, precision tooling, and prototype components for aerospace-grade requirements. Full dimensional traceability and quality documentation on every job.
Composite patterns and moulds for marine applications — from hulls and decks to complex components — as well as prototype parts for surface and subsurface products. A natural home for Sykes, with over 60 years of experience delivering high-performance marine structures. We proudly support leading Australian manufacturers including Riviera Australia, Whittley Marine Group, and Status Luxury Houseboats.
Advanced housing systems designed for speed, durability and scalable delivery. Sykes manufactures large-format composite components — including structural floor panels and modular building elements — that improve build efficiency while maintaining high performance in structural, moisture and durability requirements. Engineered for repeatability and rapid installation, these systems support modern methods of construction across residential and modular housing projects.
When standard solutions fall short, Sykes delivers bespoke façade elements, architectural forms, and GRC/FRP moulds at scale. We manufacture complex, large-format components that others can't — supporting both design-driven projects and practical civil infrastructure needs. This includes durable, corrosion-resistant plastic parts such as headwalls, pipe systems and custom assemblies.
Sykes AM can produce parts in excess of 18m × 3m, with an annual capacity exceeding 250 parts. All capabilities are delivered in-house — one team, one facility, full accountability.
Subtractive machining at a scale most manufacturers can't match. Our 5-axis CNC capability enables complex curved geometries, tight tolerances, and exceptional surface finish across foam, timber, composites, tooling boards and epoxy pastes.
Extensive composites experience across all major forms and systems. SAM is a custom pattern maker, mould maker, and OEM composite manufacturer with a proven track record producing complex laminate structures for the world's most demanding applications.
Large-format 3D printing enables the production of full-scale components without the cost and lead time of traditional tooling. By combining additive manufacturing with CNC machining, we deliver complex geometries quickly, accurately, and ready for end use or further processing.
From concept sketch to validated physical component — SAM supports design teams through the full development cycle. We offer laser scanning of physical objects to create digital twins, structural FEA analysis, weight optimisation, and rapid iteration to de-risk your development programme.
Australia's largest 5-axis CNC machine, capable of complex multi-surface machining in a single setup.
13.5m × 3.1m × 1.7m working envelopeLarge-format thermoplastic 3D printer with integrated 5-axis CNC — additive and subtractive manufacturing in one system.
6.5m × 4m × 2m envelopeFull autoclave curing capability for aerospace and high-performance composite parts requiring controlled pressure and temperature.
9m × 2.4m at 3.5 Bar & 200°CMultiple large-format post-curing ovens for thermoset composite components. Full range of sizes for any part dimension.
Up to 12m long at 200°CThree large spray booths delivering automotive grade finish. Separated paint mixing rooms and Torret spray-down booths.
Gel coat & 2-Pak to any colourIn-house metalshop specialising in TIG/MIG welding of aluminium, steel, and titanium with high production capacity. Woodworking capability for jigs and production.
Al · Steel · Titanium weldingSend us drawings, models, or a sketch. We review requirements, materials, tolerances, and timeline before committing to anything.
A transparent, itemised quote with accurate lead times. No scope creep — we define clearly before we start.
CAD/CAM optimisation, toolpath generation (Siemens NX), material and process selection — all in-house.
In-house production across machining, composites, and additive — with quality checks at every stage of the build.
Final inspection, surface finish, and delivery or collection from Geelong. We stand behind our work after handover.
CNC machining, composite tooling, additive manufacturing, post-curing, painting, and metalwork — all under one roof. We're the place customers go to get the job done, from an idea to a finished product.
Our rowing shells demonstrate our ability to build beautiful, complex, lightweight composite structures. That same expertise and quality discipline is applied to every Customer Job that enters our facility.
Fully Australian owned and operated in Geelong, Victoria. Local IP protection, responsive communication, and the accountability that offshore manufacturing can never offer.
A selection of recent work across marine, aerospace, housing, and infrastructure. Each project represents the full Sykes AM capability — from concept and tooling through to finished component.
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Whether you have detailed engineering drawings or just a concept, we're ready to talk. Get in touch to discuss your project — no obligation.
Contact Sykes AMnickb@sykes.com.au · Geelong, Victoria, Australia · Enquiries responded to within 1 business day