The Problem
Low volume production is expensive if not uneconomical in some cases.
Fyous ran a case study comparing 3D printing and traditional mould making of an RC (Remote control) car body to Polymorphic moulding. The part was printed in both MJF and FDM. And then a mould was made for vacuum forming out of recycled plastic.
FDM
Machine: Bambu labs X1 Carbon
Time: 7 hours
Cooling & Post processing: 10 minutes
Wastage: 50%
Cost: £7 per part
MJF
Machine: HP5210
Time: 12 hours
Cooling & Post processing: 24 hours
Wastage: 25%
Cost: £151 per part
CNC milling mould (In house)
Machine: Haas VF2
Set up time: 14 minutes
Time: 37 minutes
Post processing: 7 minutes
Total time: 58 minutes
Wastage: 100%
Cost: £8.47 per mould + £4 per part = £12.47
Polymorphic Moulding
Machine: PolyMo 3
Set up time: 5 minutes
Time: 20 minutes
Post processing: 0 minutes
Total time: 25 minutes
Wastage: 0%
Cost: £4 per part
The solution
PolyMorphic moulding is not only the fastest and least wasteful prototyping method but allows multiple engineering plastics for the part in this case. It also allows for instant production once the prototype is approved. No new production tooling is needed. Then, once your production run is finished, you can use the tooling for another geometry. This will enable digital stock infrastructure with no need to store moulds.