Tooling a mold to produce large parts is expensive. Companies making composite architectural panels, fiberglass boat hulls, automotive panels, etc. have to sell tens of thousands of units to recoup the cost. Furthermore, once that mold is cut, manufacturers don't just throw them away; the gigantic mold halves are placed in storage, which brings an additional cost. And when the design needs to be tweaked or updated, well, now you're paying for another mold.

A Danish company called Adapa has turned this model on its head. Adapa has created an "adaptive mold," which is a grid of vertically-oriented actuators that support a membrane above.

Each actuator moves independently into position to form the membrane into the desired shape.

Then the material—fiberglass, concrete, carbon fiber, thermoplastic, etc.—is laid over the membrane, and that material's curing process is enacted.

The company says the system is good for about a thousand castings before you'd need to start replacing or servicing components; for instance the membrane will eventually break down, and the motors for the actuators may need to be recalibrated or replaced. But for a subset of manufacturers, the advantages will outweigh the relatively low production volume. Design changes can be put into production instantly, without waiting or paying for retooling. The system uses less manpower than traditional molding. And there is no tooling to be stored afterwards.

Adapa makes several different models, with their largest able to cast objects roughly 11' by 17'. Additionally, they make smaller versions that they rent, including a "Mini" version with an envelope just 2' by 2'.

Here's how it works:

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