Sheffield-based manufacturing startup Fyous has unveiled its pioneering PolyMorphic 28K molding technology at the RAPID + TCT 2024 event. Co-Founders Joshua Shires and Thomas Bloomfield have developed this innovative technology, which offers a flexible and efficient approach to mold creation. The patent-pending design utilises over 28,000 densely packed pins that adjust automatically to create molds in just minutes, capable of withstanding up to six tonnes of distributed pressure and being reshaped repeatedly, eliminating traditional tooling processes and reducing waste.
PolyMorphic molding operates with zero tooling waste and boasts production speeds up to 14 times faster than 3D printing. Fyous’ software generates the shape for the PolyMorphic mold from a 3D CAD model, and the PolyMorphic machine transforms the mold to produce the desired product. After production, the mold returns to the machine, ready to be reshaped for the next use. This innovative technology can be widely applied to various manufacturing processes, such as vacuum forming, foam casting, food production, or composite layup, among others.
The versatility and potential of PolyMorphic molding to accelerate product development across industries are points of particular interest. Fyous is conducting ongoing research to discover new applications and advance sustainable manufacturing practices, similar to the initial exploration period of 3D printing. The company aims to innovate while minimising environmental impact by conserving raw materials and streamlining production cycles.
Other players in the manufacturing industry have also been developing innovative injection molding technologies. For instance, Denmark-based manufacturing provider AddiFab introduced Freeform Injection Molding (FIM) in 2019, merging additive manufacturing with formative processes to advance prototyping. Additionally, back in 2021, Massivit 3D introduced the Massivit 10000 3D printer featuring Cast-In-Motion (CIM) technology, aimed at enhancing the production of large-format composite molds.
In conclusion, Fyous’ PolyMorphic 28K molding technology marks an exciting advancement in the manufacturing industry, demonstrating great potential in terms of accelerating production processes and reducing waste. It stands as evidence of the ongoing innovation and evolution within the manufacturing sector, with a focus on efficiency and sustainability.