Workholding in complex manufacturing Fyous launches quick-change, zero-waste tooling for large and unique parts

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Efficient workholding for large, complex parts has long posed challenges for sectors like aerospace and automotive, but Fyous’ new reusable tooling technology offers a potential breakthrough. Using an innovative pin-based forming machine driven by 3D CAD models, the company can create custom tooling in minutes without waste, eliminating the need for traditional fixtures.

Holding large, complex pieces for machining is a long-standing challenge in manufacturing, but Fyous says rapidly made reusable tooling can solve it, eliminating the need for multiple fixtures, such as vices and jigs, saving time and money.

Sectors such as aerospace and automotive frequently need to hold large, complex, and often unique pieces for machining, so the ability to make custom tooling quickly, cost-effectively, and with zero waste, is potentially game-changing. Fyous, based in Sheffield, has developed an ultrafast tooling technology based on an infinitely reusable pin tool that is inserted into a forming machine, which is driven by a 3D CAD model to form the 28,000 densely-packed pins into the tooling shape.

Josua Shires, co-founder at Fyous, commented: “Because custom tooling can be made very quickly, it is possible to secure even the largest and most complex piece. The only input is a 3D CAD model of the part to be held, from which we can produce tooling that hold the part perfectly. Failure to use optimal workholding is not only inefficient, expensive and time-consuming, it can result in slippage, safety risks, and increased chance of damaging parts.”

Due to their strength, the pin tools are also perfectly suited for holding metal for machining. The positioning of the pins is accurate to within 0.1 mm, and once locked in position can withstand six tonnes of pressure, making them perfect for use in vacuum forming, composite layup, composite bonding and moulding polyurethane (PU) products.

This Polymorphic moulding process takes around twenty minutes, which is about fourteen times faster that 3D printing for an equivalent sized part, the company states. Each pin tool is about the size of a laptop or shoebox, and they can be used together to make bigger moulds for multiple applications.

Shires added: “Good workholding increases productivity and efficiency by reducing the time and effort required to set up pieces for machining, leading to significant cost savings and improved quality.”

Critically, once the pin tool has been used it can be reinserted into the forming machine to create a new mould shape with zero waste. There is no need to store the mould, just the 3D CAD model.

The product consists of a forming machine (the Polymorphic Forming Machine), pin tool (the 28k Polymorphic Tool) and 3D CAD software (Pinpoint).

Joshua Shires concluded: “With the ability to produce perfectly designed custom tooling in minutes, manufacturers can now be confident of handling even the largest, most awkward or cumbersome piece, with no fear of damage. We believe the PolyMorphic Forming Machine will transform both manufacturing and prototyping across a wide range of sectors, and we look forward to seeing how it will be deployed to transform workholding for large or complex parts.”

The official unveiling of the Poly,orphic Forming Machine will happen at 11 o’clock on November 19th at Formnext, which runs between November 19th and 22nd and takes place in Messe Frankfurt, Germany. Fyous is on Stand 11.1, E48.

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