Fyous will premiere the PolyMorphic 28k at Formnext in Germany in November 2024. The equipment uses densely packed pins to create custom molds in minutes, and consists of the pin tool plus a forming machine into which the pin tool is inserted.
A 3D CAD model of the mold to be formed is used to move the pins into position. As a result, the technology can create a mold in 20 minutes. Rapid prototyping is one of the key advantages and applications of the technology, specifically when the number of iterations starts to increase.
The positioning of the pins is accurate to within 0.1mm. Once locked in position, the pins can withstand six metric tons of pressure, making them perfect for vacuum forming, composite layup, composite bonding, work holding and molding polyurethane (PU) products. The product has been in development for the last five years.
The pin tool is about the size of a laptop or shoebox and can be reinserted into the forming machine to create a new mold shape with zero waste. There is no need to store the mold, thanks to the 3D CAD model. Fyous reports that the new technology is set to revolutionize the world of prototyping, customizable production and complex tool holding.
Josh Shires, co-founder of Fyous, said, “PolyMorphic molding is not only fast but also has virtually zero waste, making it highly sustainable. This makes the system perfect for products that demand minor customization, and for prototyping, which can be highly costly if you go through multiple iterations.”
The technology can be applied to many sectors, from aerospace and automotive to packaging and toys. The PolyMorphic 28k will be live on the Fyous booth at Formnext, and there will be demonstrations throughout each day of the show.