17. ToffeeX: speeding up AI printing for complex components

Founders: Marco Pietropaoli, Francesco Montomoli, and Audrey Gaymann
Year founded: 2019
Website: toffeex.com

3D printing has opened up a world of possibility. From body armour to houses, the process (also known as Additive Manufacturing or AM) has made it possible to realise intricate blueprints in minutes. But while production might be fast, the design stage remains slow.

ToffeeX (rebranded from ToffeeAM at the start of this year) is a generative design software that is able to produce intelligent, complex, and efficient components suitable for AM. 

We’re not talking kid’s play, here. ToffeeX’s specialty is thermo-fluid components. You might know them as the pumps and valves that make up your heating system or car engine. 

Finding a way to make these designs more efficient for consumers, and thereby save on production costs, has been an Everest-like ambition for global manufacturers. ToffeeX has cracked the code by building something called fluid topology optimisation into its platform.

The process can identify the most advantageous fluid flow regions for energy transfer. Using it, manufacturers in sectors like aerospace and automotive are able to create first-class components that not only work, but can also be produced at scale.

ToffeeX’s solutions are up to 40% more efficient and can be produced 20 times faster in Additive Manufacturing (although the process can also be applied to traditional manufacturing). 

Naturally, this has added benefits for reducing waste and energy usage, a key challenge for an industry that was reportedly responsible for 50% of global emissions in 2024.

“The current engineering research and development process is expensive and very time consuming,” says the team. “Our net zero targets require us to accelerate our path to sustainability beyond the pace provided by current solutions.”

ToffeeX raised £5m in Series A funding at the start of last year. To date, it counts Boeing, Rolls-Royce, and several Formula 1 racing car teams among its client base, but it has the potential to expand into all engineering categories, including construction and civil.

Manufacturers: can’t build a complex aircraft heat exchanger for toffee? You need ToffeeX.