The Challenge
Large, customised or low-volume tooling can involve substantial fabrication time and cost. Design changes may require additional machining or rework, while supplier lead times and freight can delay production.
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Long lead times before production can start
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Dependence on external suppliers and freight
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High fabrication costs for large or one-off tools
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Additional time and cost when designs change
The Solution
Hyperion uses large-format 3D printing to produce custom moulds, plugs, patterns and fixtures directly from digital designs. This approach can reduce fabrication time and cost for large or low-volume tooling, with production available at Hyperion or closer to your project through a deployed system.
Application pathways
Application pathways and production outputs for tooling, moulds, plugs, patterns, fixtures, and production aids.
Applications
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Uncrewed Surface Vessel (USV) hulls
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Maritime surveillance platforms
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Autonomous inspection systems
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Modular payload structures
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Rapid prototyping and testing
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Maritime security and ISR applications
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Mission-specific vessel configurations
Outputs
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Large-format vessel hulls
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Process window development and optimisation
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Structural maritime components
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Modular payload housings
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Prototype autonomous platforms
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Custom tooling and fixtures
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Deployable operational components
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Marine infrastructure systems
FREQUENTLY ASKED QUESTIONS
What else should you know about large-format tooling and moulds?
Common questions from teams weighing additive tooling against conventional toolmaking.
Q1.
What is large-format additive tooling?
Moulds, plugs, patterns, formwork and fixtures produced using large-format 3D printing. The printed form can then be machined or finished to meet the application’s dimensional and surface requirements.
Q2.
How long does it take to produce a custom mould?
Large and oversized moulds up to 4m × 2m × 2m, composite tooling, plugs and patterns that are difficult, slow or costly to source through traditional toolmakers.
Q3.
How long does it take to produce a custom mould?
Lead time depends on the mould’s size, geometry, material and finishing requirements. The delivery schedule accounts for printing, machining, surface treatment and inspection where required.
Q4.
How does 3D-printed tooling compare to conventional toolmaking?
Additive manufacturing can reduce fabrication steps for large, complex or low-volume tools. Its suitability depends on the required surface finish, tolerances, processing conditions and tool life.
Q5.
What materials are used for additively manufactured tooling?
Engineered polymer materials, including recycled feedstock where suitable, matched to the demands of the application. See Polymers and Testing and Validation.
Q6.
Can Hyperion produce one-off patterns, plugs and fixtures?
Yes. Hyperion can produce custom patterns, plugs and fixtures from digital models, with material selection and finishing matched to their intended use.Yes. Hyperion can produce custom patterns, plugs and fixtures from digital models, with material selection and finishing matched to their intended use.