Fyous Unveils Infinitely Reusable Manufacturing Mold

Fyous, a digital casting company, is launching the world’s first infinitely reusable casting technology – PolyMorphic casting – at this month’s RAPID + TCT event in Los Angeles. While it’s not AM, it’s still interesting from a general digital production perspective. The company’s technology can change in less than 20 minutes – producing zero tooling waste and making usable parts 14 times faster than 3D printing. The technology, designed and built by Fyous co-founders Joshua Shires and Thomas Bloomfield, contains more than 28,000 densely packed needles that create the mold. Once the pins are in place, the mold can withstand six tons of distributed pressure.

Metamorphic in nature, patent-pending PolyMorphic casting has the potential to transform the manufacturing industry – reducing waste generated by tool repair, along with faster production times compared to 3D printing and traditional mold making. By inputting a 3D CAD model, the Fyous software generates the shape of the PolyMorphic mold, and then the machine changes the shape of the mold to create the desired product. The product manufacture could be anything you would normally use a mold for. For example, vacuum forming, foam casting, food production or composite coating – to name a few.

“Our mission is to deliver revolutionary casting technology that will disrupt the prototyping and manufacturing sectors around the world,” said Joshua Shires, co-founder of Fyous. “Using PolyMorphic casting to rapidly create precise tooling molds will reduce time-to-market for a wide range of products, plus unlock commercial viability for desired products that currently lack a cost-effective manufacturing method… It’s a technology without waste where the raw materials are preserved and the molds can be used again and again. We will not only eliminate physical waste in the form of materials and tools, but also eliminate wasted time by accelerating product development, prototyping and manufacturing efficiency.”

“The new technology can generate products up to 14 times faster than conventional 3D printing methods, with zero waste. PolyMorphic casting supports a wide range of materials and processes, including casting and casting, vacuum forming and composite coating,” said Thomas Bloomfield, co-founder of Fyous. “This versatility makes its possible applications almost limitless. Just like when 3D printing was developed, the applications it could be used for were unknown to its inventors. The Fyous team is now undertaking this period of discovery with PolyMorphic casting, revealing potential applications for this technology at an exponential rate.”

The Fyous team will be exhibiting at RAPID + TCT in Los Angeles, June 25-27 at the LA Convention Center at booth #2763.