The Challenge
Conventional toolmaking is slow, expensive and poorly suited to large-format, low-volume or iterative requirements. A single tooling revision can stall a project, and once a tool is committed, design flexibility is largely lost.
01 /
Long lead times before production can start
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Dependence on external suppliers and freight
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High cost for low-volume or one-off tooling
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Limited ability to revise a design once tooling is committed
The Solution
Hyperion produces large-format tooling, moulds and fixtures directly from digital design, removing the conventional toolmaking step and giving projects the flexibility to iterate before committing to production. Depending on the project, this capability can be delivered in-house or through deployable production positioned closer to where the work happens.
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?
Large-format additive tooling is moulds, patterns, plugs, formwork and fixtures produced directly from digital design using large-format additive manufacturing, without the conventional hard-tooling step.
Q2.
What size moulds and tooling can Hyperion produce?
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?
Typically hours to days, depending on the size and geometry of the mould and how many are required. Because tooling is produced directly from digital design without the conventional hard-tooling step, lead times are compressed well below traditional toolmaking, which often runs to weeks.
Q4.
How does 3D-printed tooling compare to conventional toolmaking?
Producing tooling additively compresses the timeline from design to usable tooling and keeps designs flexible before commitment. Conventional toolmaking is slow, expensive and poorly suited to large-format, low-volume or iterative work, and once a tool is committed, design flexibility is largely lost.
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 — because tooling is produced directly from digital models, one-off patterns, plugs and fixtures are economical to produce without the cost and delay of conventional tooling for low volumes.