EngineeringHybrid manufacturingProduct Launch

Fyous unveils infinitely reusable manufacturing mold

PolyMorphic molding features more than 28,000 densely packed, software-controlled pins that can withstand six tonnes of distributed pressure

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Fyous, a digital molding company, is launching the world’s first, infinitely reusable molding technology – PolyMorphic molding – at this month’s RAPID + TCT event in Los Angeles. Although it is not AM, it is still exciting from a general digital manufacturing perspective. The company’s technology can shapeshift in under 20 minutes – producing zero tooling waste and making usable parts reportedly 14x faster than 3D printing. The technology, devised and engineered by Fyous’ Co-founders Joshua Shires and Thomas Bloomfield, features more than 28,000 densely packed pins that create the mold. Once the pins are in position, the mold can withstand six tonnes of distributed pressure.

Metamorphic by nature, the patent-pending PolyMorphic molding has the potential to transform the manufacturing industry – reducing the waste generated through tooling amends, coupled with faster production times compared to 3D printing and traditional mold-making. By inputting a 3D CAD model, Fyous software generates the PolyMorphic mold shape, and the machine then shapeshifts the mold to create the intended product. Product manufacturing could be anything for which you would typically use a mold. For example, vacuum forming, foam casting, food production, or composite layup – to name a few.

Fyous unveils PolyMorphic molding technology featuring more than 28,000 densely packed, software-controlled pins.

“Our mission is to deliver a revolutionary molding technology that will disrupt prototyping and manufacturing sectors worldwide,” said Joshua Shires, Co-founder of Fyous. “Using PolyMorphic molding to rapidly create accurate molds for tooling will reduce time to market for a huge array of products, plus unlock commercial viability for desirable products which currently have no cost-effective manufacture method… It is a zero-waste technology where raw materials are conserved and the molds can be used again and again. We will remove not only physical waste in the form of materials and tooling but also remove wasted time by accelerating product development, prototyping, and manufacturing efficiencies.”

“The new technology can generate products up to 14 times faster than conventional 3D printing methods, with zero-waste. PolyMorphic molding supports a wide array of materials and processes, including molding and casting, vacuum forming, and composite lay-up,” said Thomas Bloomfield, Co-founder of Fyous. “This versatility makes its possible applications almost limitless. Much like when 3D printing was developed, the applications it could potentially be used for were unknown by its inventors. The Fyous team is now undertaking this period of discovery with PolyMorphic molding, uncovering potential applications for this technology at an exponential rate.”

The Fyous team will be exhibiting at RAPID + TCT in Los Angeles, on 25th-27th June, at the LA Convention Center at stand #2763.

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Consumer Products AM 2024

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