PolyMorphic Moulding technology uses 28,000 digitally controlled pins to create a shape from a 3D CAD shape in less than 20 minutes, achieving zero waste and enabling parts production 14 times faster than 3D printing.

Fyous (Sheffield, U.K.) is launching what it claims is the world’s first infinitely reusable molding technology, PolyMorphic Moulding. Fyous’ technology can shape-shift in under 20 minutes, producing zero tooling waste and making usable parts 14 times faster than 3D printing.

The technology, devised and engineered by co-founders Joshua Shires and Thomas Bloomfield, features more than 28,000 densely packed pins that create the mold. Once the pins are in position, the mold can withstand 6 tonnes of distributed pressure.

Metamorphic by nature, Fyous’ patent-pending PolyMorphic Moulding reportedly has the potential to transform the manufacturing industry, reducing the waste generated through tooling amends, coupled with faster production times compared to 3D printing and traditional moldmaking.

By inputting a 3D CAD model, Fyous software generates the PolyMorphic mold shape. The PolyMorphic machine then shape-shifts the mold to create the intended product. Once product manufacture is complete, the PolyMorphic mold is returned to the machine, ready for the next shape-shift. Product manufacturing methods compatible with this technology include those typically used with a mold.

“PolyMorphic Moulding supports a wide array of materials and processes, including molding and casting, vacuum forming and composite layup,” says Thomas Bloomfield, Fyous co-founder. “This versatility makes its possible applications almost limitless. 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.”