Labelled ‘PolyMorphic Moulding’, the new manufacturing technique uses a reusable moulding bed with over 28,000 pins. CAD models are fed into the platform, adjusting the pins precisely into the desired shape of the PolyMorphic Mould. According to Fyous, the technology can be used to create parts 14 times faster than 3D printing with zero tooling waste, and the mould can be reset into different positions in 20 minutes.
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"Our mission is to deliver a revolutionary moulding technology that will disrupt prototyping and manufacturing sectors worldwide,” Fyous co-founder, Joshua Shires said in a statement.
"Using PolyMorphic moulding to rapidly create accurate moulds 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.
"Our mission is to deliver this disruption whilst reducing environmental impact. PolyMorphic moulding is a zero-waste technology where raw materials are conserved and the moulds 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 manufacture efficiencies."
According to Fyous, once the platform’s pins are set in position, the mould can withstand six tonnes of distributed pressure. The patent-pending technology also supports a variety of materials and processes including moulding, casting, vacuum forming and composite layup. Fyous has previously used PolyMorphic moulding to create bespoke footwear for diabetic patients and is now looking to establish commercial partnerships.
"[PolyMorphic moulding's] versatility makes its possible applications almost limitless,” said Fyous co-founder Thomas Bloomfield.
“Much like when 3D printing was developed, the applications it could potentially be used for was unknown by its inventors. The Fyous team is now undertaking this period of discovery with PolyMorphic moulding, uncovering potential applications for this technology at an exponential rate."
The Fyous team will be exhibiting at RAPID + TCT in Los Angeles, 25th-27th June at the LA Convention Center, stand 2763.
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