A specialised plastic component measuring no larger than the palm of a hand is celebrating its tenth anniversary. The Polyman teaching aid has established itself as an indispensable resource for educational institutions, technical academies and industrial enterprises worldwide. It conveys essential engineering competencies in mould making and injection moulding through tactile design analysis.
The initiative originated with Professor Steffen Ritter of Reutlingen University, who spearheaded and coordinated the development project. The VDWF subsequently brought the concept to fruition in cooperation with multiple industrial partners from its broader network. The two-component polyethylene model enables direct comparative analysis of component engineering. The defective orange side highlights common design flaws, including inadequate draft angles, non-uniform wall thicknesses, structural warping and prominent sink marks. In contrast, the optimised blue side demonstrates sound engineering practices, showcasing proper component architecture, efficient mould construction using a minimal number of components, and the integration of functional features in a technically sound manner. By enabling users to physically identify design deviations on one side while observing integrated technical solutions on the other, the model translates complex geometrical principles into a tangible educational experience.
Even after a decade of continuous use, Professor Ritter remains convinced of the enduring value of this compact educational tool, emphasising that the Polyman is as relevant today as it was when it was first developed. It provides apprentices, university students and industry professionals with a practical foundation for understanding the core principles of injection moulding design.
Following its initial launch at Moulding Expo 2017, where units were produced live at the VDWF joint exhibition, subsequent manufacturing was undertaken by Schmalkalden University of Applied Sciences. To date, around 40,000 units have been distributed internationally within the sector. Professor Ritter notes that the Polyman's primary advantage lies in its physical accessibility. Being able to handle the model directly facilitates knowledge transfer far more effectively than standard theoretical presentations, enabling concepts to be understood both literally and intellectually for improved retention.
This tangible methodology has established the Polyman as a highly versatile educational and communication tool in industries around the world. Beyond academic applications, the component serves multiple roles within professional engineering environments. Senior designers use the two-colour part to mentor junior engineering personnel, conduct internal design reviews and refresh foundational knowledge. Furthermore, units are often kept in conference facilities to serve as visual reference models during commercial and technical client discussions, replacing abstract deliberations about draft angles or variations in wall thickness with direct physical demonstration. The physical model is complemented by an instructional fold-out brochure detailing specific structural characteristics and referencing fundamental injection moulding design guidelines.
In response to advances in manufacturing technology, the Polyman portfolio has expanded to include specialised derivatives. The product family now includes a green structural component that demonstrates the principles of chemical and physical foaming processes, as well as an immersive virtual reality (VR) application. Using the VR simulation, users wearing a head-mounted display can navigate a virtual, transparent Polyman mould to observe, control and analyse melt-filling dynamics from any perspective. This gives them a comprehensive understanding of material-specific flow behaviour and design parameters.
Polyman has firmly established itself within the modern training framework of the tool and mould-making sector. By providing clear, vivid visualisation, the initiative continues to accelerate learning curves and support technical precision throughout the international tooling community.
