Reshaping aerospace innovation with the Mayku Multiplier at Bristol University

At Bristol University’s aerospace department, students combine analytical methods with hands-on experimentation to design and build innovative aerospace applications.

Previously, the team relied on fabrication methods like 3D printing and traditional molding, which required the creation of intricate mold tools. These processes were often cumbersome and time-intensive, with a single iteration taking days or even weeks to complete.

Introducing the Mayku Multiplier and its pressure forming technology has transformed their workflow, making mold creation faster, more efficient, and highly accessible. What once took days can now be achieved in seconds, allowing several iterations in a single day. This opens doors for advanced research and exploration, empowering Dr. Ian Farrow and his students to bring their prototypes to life with unprecedented speed and precision.

A standout feature of the Multiplier is its remarkable consistency. As Dr. Farrow notes, this level of precision is essential for academic testing, where controlled conditions are critical. For the students, the pressure former feels like having a “mini factory” at their fingertips, delivering professional-grade results without the complexity of industrial-scale equipment.

The Multiplier has also unlocked opportunities for students to explore new materials and innovative applications. Dr. Farrow highlights the use of auxetic materials – specialized materials with a negative Poisson’s ratio that expand rather than contract when stretched. These materials hold incredible potential for applications like prosthetics and body supports, offering improved fit and comfort. The Multiplier has been used by students to create auxetic plastic samples, an accomplishment that would have been far more challenging with other fabrication methods.

Beyond materials experimentation, the Multiplier has enabled groundbreaking projects in customization. For example, students used 3D scanning and thermoforming to create a custom pad by molding plastic sheets onto a scan of a leg. This hands-on process demonstrates the versatility of the Multiplier and its ability to integrate with other modern manufacturing techniques, like 3D printing. Instead of relying solely on 3D printing for prototypes – which can be limited in strength and efficiency – the Multiplier allows students to take their designs a step further, creating durable and functional end-use parts.

The machine’s ability to handle complex designs is another game-changer. One project pushed the limits of the pressure former by designing tailored sockets for lower-limb prosthetics. These sockets incorporate auxetic properties to improve comfort and adaptability, demonstrating how the Multiplier excels at handling intricate molds and challenging designs. By simplifying the tooling process, the pressure former enabled the team to produce accurate, functional results in record time.

For Bristol University’s Aerospace Department, the Multiplier isn’t just a tool – it’s a catalyst for learning, innovation, and creativity. Students gain valuable hands-on experience, exploring ideas that would have been too costly or time-consuming to test before. The rapid iteration capability fosters a deeper understanding of design principles and accelerates development, preparing the next generation of aerospace engineers for real-world challenges.

Whether it’s exploring niche areas like impact testing for thermoforming and 3D printing, or crafting practical solutions like prosthetic sockets, the Multiplier has become an essential part of the department’s workflow. It empowers students and researchers alike to think bigger, iterate faster, and create smarter.