Polymorphic moulding Fyous to debut ultrafast mould-making technology at Formnext

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Fyous is set to debut its groundbreaking mould-making technology, the Polymorphic 28k, at Formnext 2024. The event, which will be held from November 19th to 22nd in Frankfurt, Germany, will mark the first public demonstration of this innovative system that promises to transform prototyping and customisable production.

The Polymorphic 28k, developed over the last five years by Fyous in Sheffield, utilises 28,000 densely packed pins to create custom moulds in around 20 minutes, significantly faster than traditional methods. The system combines a pin tool with a forming machine, where the pin tool is inserted. Using a 3D CAD model of the desired mould, the pins are accurately positioned to within 0.1 mm, creating the required shape.

Once in position, the pins can withstand up to six tonnes of pressure, making them ideal for applications such as vacuum forming, composite layup, composite bonding, workholding, and moulding polyurethane (PU) products. Importantly, the pin tool can be reused multiple times to form different moulds without generating waste, as there is no need to store physical moulds — only the CAD model.

This ultrafast mould-making process, known as ‘Polymorphic moulding’, is around 14 times faster than 3D printing for a comparable-sized part, offering significant time-saving advantages. The pin tools, roughly the size of a laptop or shoebox, can also be combined to create larger moulds, further expanding the system's versatility across a wide range of industries.

Josh Shires, co-founder of Fyous, emphasised the system’s potential, noting that it offers a cost-effective and sustainable solution for manufacturers seeking to meet the growing demand for customised products. “Polymorphic moulding is not only fast but also has virtually zero waste, making it highly sustainable,” said Shires. He explained that the technology is particularly well-suited for products requiring minor customisation and for prototyping, where the ability to create multiple iterations without excessive costs is crucial.

The Polymorphic 28k has already delivered significant time and cost savings for manufacturers in the dental aligner and medical footwear sectors. Additionally, its strength and precision make it ideal for workholding applications in industries like aerospace and automotive, where securely holding complex parts for machining can be challenging.

Shires further highlighted the system's adaptability: “There’s no need to make multiple moulds; simply store the CAD models and re-programme the machine as needed.” This capability makes the Polymorphic 28k a versatile tool for manufacturers across sectors, including packaging, toys, and beyond.

The unveiling of the Polymorphic 28k will take place at 11:00 AM on November 19th at the Fyous stand at Formnext, with live demonstrations available throughout the exhibition. Shires expressed excitement about the future of the technology, stating: “We can now see for the first time a way to realise the ‘made-on-demand’ model of consumer product manufacturing. The possibilities are limitless, and we are very excited to be at the heart of this revolution.”

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