Sheffield-based Fyous has developed its PolyMorphic Forming Machine to address one of manufacturing’s persistent problems – securely holding large, complex parts during machining. The system uses 28,000 densely-packed pins that automatically configure to any shape based on a 3D CAD model, eliminating the need for multiple custom fixtures.
Ultrafast, Precise, and Strong
The technology positions pins with 0.1mm accuracy, locking them to withstand six tonnes of pressure—ideal for vacuum forming, composite layup, and molding. Unlike traditional methods requiring bespoke jigs, Fyous’ system creates reusable tooling in just 20 minutes—14x faster than 3D printing comparable parts.
CAD-Driven Efficiency
“Simply upload your 3D model, and our machine produces perfectly fitted tooling,” said Joshua Shires, Fyous co-founder. This approach prevents slippage, part damage, and safety risks while slashing costs and setup time compared to conventional workholding.
Broad Industrial Applications
The PolyMorphic moulding process supports:
- Aerospace composite fabrication
- Automotive prototyping
- PU product molding
Its rapid reconfigurability makes it valuable for low-volume, high-mix production where traditional fixtures are impractical.
The Future of Adaptive Manufacturing
By merging digital design with physical adaptability, Fyous’ innovation could redefine large-part workholding. As industries demand faster changeovers and greater flexibility, such reconfigurable tooling systems may become essential for next-gen factories.
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