James Birkett’s entrepreneurial journey began with a mechanical engineering apprenticeship, where he learned to design 3D products and parts. The turning point came when he moved to a smaller company and needed to check his own designs before committing to large orders.

Using his hobby 3D printer at home, he started printing test parts, which soon caught the attention of other companies who needed the same service. As demand grew, James invested in more printers, and his side project quickly became Flex 3D Printing Ltd.

As orders surged, James launched a website and relocated operations from his living room to a rented office. By 2022, he shifted from full-time to part-time at his job to focus more on the business and brought in two Co-Founders to help tackle the growing demand.

Seeking business coaching with Worcestershire County Council

It was at this crucial juncture that James reached out to Enterprising Worcestershire, Worcestershire County Council’s business coaching programme, facilitated by Real World Consultancy (RWC).

Paired with an experienced business mentor, James and his team sat down to evaluate the future of the business. James admitted that despite their successes, he was spending too much time in the day-to-day operations rather than growing the business in a meaningful way.

James, Tom, and Aidan worked closely with their Enterprising Worcestershire coach to identify bottlenecks in their processes and develop a comprehensive plan for growth. “We were supported to make realistic plans and reviewed different areas of the business carefully," James recalls. "This led to a major investment into custom software to enable faster order quoting and better production workflows.”

With the specialist guidance, the team implemented scalable systems and hired a 3D artist for design work. Soon after, Tom joined full-time, as their Finance Director and Production Manager, streamlining operations. Aidan, a talented software engineer, focused on developing the website and improving the order management systems.

Scaling up and looking ahead

With the help of RWC, Flex 3D Printing Ltd gained momentum, optimising systems to handle increasing demand. For James, however, this was just the beginning. He is now focused on long-term growth and expanding the company’s reach beyond local clients.

Based in Hallow, North Worcester, Flex 3D Printing Ltd primarily serves the Midlands, but James has larger ambitions. The company recently invested in a machine capable of producing industrial-grade nylon parts—a material offering with very few UK competitors. This new capability enables Flex 3D to cater to a broader clientele, including industrial B2C users, positioning them as a regional leader.

James' engineering background and hands-on approach have been key to the growth of Flex 3D Printing, but he recognises the need to keep evolving. “I want to focus on more long-term thinking and marketing,” he says. His collaboration with RWC through the business coaching initiative has laid the foundation for the next phase of growth, as Flex 3D expands its capabilities, takes on more batch manufacturing work, and strengthens its presence as one of the fastest services in the industrial 3D parts market.

Flex 3D Printing Ltd. is a testament to the power of turning a hobby into a thriving business, the value of strategic coaching, and the importance of staying open to new opportunities in an ever-evolving market.

James Birkett’s journey from a Mechanical Engineer tinkering with a hobby 3D printer to becoming the founder of a growing 3D printing business is both inspiring and instructive. With the right guidance and a focus on long-term growth, Flex 3D is poised to continue its trajectory as a key player in the UK’s 3D printing industry.