Client Overview

AeroForm Labs is a UK-based aerospace engineering group specialising in lightweight composite structures for next-generation UAV platforms. Their work demands rapid iteration, strict tolerances, and the ability to validate multiple geometries under tight deadlines.

The Challenge

AeroForm Labs needed to produce a wide range of composite prototype parts — from aerodynamic fairings to internal ducting — but were slowed by traditional tooling. Each new mould required:

• 6–10 weeks of lead time

• Significant material and machining costs

• Limited ability to iterate after initial production

• Complex storage and logistics for physical moulds

The bottleneck stalled R&D cycles and restricted their ability to test multiple design variations.

The Solution

Fyous introduced AeroForm Labs to PolyMorphic Manufacturing through the PF-01 PolyMorphic Forming Machine. Using thousands of digitally controlled pins, the team could generate fully reconfigurable moulds in minutes — perfect for low-volume composite layups.

Together, Fyous and AeroForm Labs:

• Defined the required forming area and pin resolution

• Developed a custom forming workflow suitable for advanced carbon composites

• Integrated the PF-01 into their existing R&D cell

• Trained their engineers to iterate, test, and re-form geometries on demand

The Results

Within weeks of deployment, AeroForm Labs reported dramatic improvements:

• 78% reduction in prototype development time

• Zero tooling waste, replacing multiple carbon or CNC-machined moulds

• 10+ geometry variations tested using the same forming surface

• £42,000 saved in tooling and machining costs during a single testing cycle

• Ability to move from CAD to layup-ready moulds in under 12 minutes

The PolyMorphic process allowed their team to iterate rapidly, test more aggressively, and move validated designs to final production with unprecedented speed.

Why It Matters

AeroForm Labs now runs their PF-01 as a central part of their R&D workflow. Instead of waiting for new tools, engineers adapt the machine in real time — enabling smarter design decisions and reducing environmental impact.

PolyMorphic Manufacturing didn’t just speed up production; it fundamentally changed how their team approaches innovation.

Client Quote

“The PF-01 has become the most valuable tool in our lab. We can test ideas the moment they’re modelled — it’s completely transformed our pace of development.”

— Lucas Grant, R&D Lead, AeroForm Labs

Services Provided

– PolyMorphic System Integration

– Custom Workflow Development

– Engineering Support & Training

– On-Site R&D Collaboration

Technology Used

– PF-01 PolyMorphic Forming Machine

– Fyous PolyMorphic Control Suite

– Custom composite layup workflow