Services
Rapid Prototyping
Appearance models, structural prototypes, functional samples and show units — built by CNC, 3D printing or vacuum casting depending on what the prototype has to prove.
A prototype is not a display piece; it exists to answer a specific question. Is the colour right? Does it assemble? How does the button feel? Are the assembly clearances adequate? Different questions call for different processes, which is why we always ask what a prototype has to prove before quoting it.
For appearance, machined acrylic or ABS with paint gets closest to production surface quality. For structure and assembly, machined engineering plastic or metal. If you only need to confirm proportion and form, 3D printing is fastest and cheapest.
Capabilities
- Processes
- CNC machining, SLA/SLS/MJF printing, vacuum casting — combined to suit the objective
- Typical lead time
- 3–5 working days for simple appearance parts; 5–10 with paint and assembly
- Quantity
- Typically 1–50 sets; beyond that vacuum casting is usually the better route
- Deliverables
- Single parts, full assembly kits, working mechanisms, exhibition units
Solutions
Appearance models
For colour, texture and proportion sign-off, finished close to production quality, with screen printing, laser marking and logos.
Structural prototypes
To verify assembly relationships, snap fits, boss strength and service sequence — usually in machined engineering plastic or metal.
Functional samples
Assembled with electronics and moving parts for real testing, in materials chosen to approximate production behaviour.
Exhibition and photography units
Appearance-led complete units for shows, with lead time and cosmetic standard agreed up front.
Process Overview
Prototyping is a process-selection problem, not an equipment problem. For form sign-off on a housing, an SLA print in half a day is enough. For a drop test, it has to be machined ABS or PC — printed parts are anisotropic between layers, and the test data would not mean anything.
So we start from the question this iteration has to answer, work back to material and process, and where necessary build the same set of parts two different ways.
Materials
- ABS, PC, PC/ABS (structural and functional verification)
- PMMA acrylic (transparent parts, light guides)
- POM and nylon (moving parts, gears, sliders)
- Aluminium 6061 (metal structure and heat-sink parts)
- SLA photopolymer (form sign-off, fine detail)
- SLS nylon PA12 (complex geometry, no support structures)
Surface Finishes
- Bead blasting
- Painting (matt, satin, gloss)
- Polishing and coating of clear parts
- Screen and pad printing
- Laser marking
- Plating and vacuum metallising
- Assembly and bonding
Tolerances & Size Limits
- CNC machined
- ±0.05–0.1 mm
- SLA printed
- ±0.1 mm or ±0.1%, whichever is greater
- SLS / MJF
- ±0.2 mm or ±0.2%, whichever is greater
- Assembly clearance
- Allow 0.1–0.2 mm on sliding fits; snap fits assessed against material stiffness
Design Guide (DFM)
State the objective first
Appearance, structure or functional test — that choice sets material, process and the cost bracket.
Allow stock on clear parts
Polishing acrylic removes material. Leave 0.1–0.2 mm on critical mating dimensions.
Paint adds thickness
Typically 0.05–0.15 mm per coated face. Mask mating surfaces and snap features.
Design snap fits for the real material
Printed snap features break early. Verify structure in injection-grade machined material, not in a print.
Bosses and inserts
Machine threads directly or press in brass inserts. Do not rely on self-tapping threads in prototype parts.
Quality Control
- Critical dimensions and mating faces checked against the drawing
- Cosmetic parts judged against the approved sample for colour, particles and runs
- Assembly verification before shipping complete units
- Photographs supplied at shipment for remote sign-off
FAQ
How does a prototype differ from a production part?
Mainly in material condition and process. Machined ABS and moulded ABS differ in strength, shrinkage and surface texture, so structural conclusions carry over but fatigue and ageing data do not.
Can I send only renders or sketches?
We can discuss the project from those, but a formal quote needs a 3D file. If you only have 2D drawings or renders, we can model it for you and quote the modelling separately.
How good can transparent parts get?
Machined and polished acrylic reaches high clarity, enough for appearance and light-guide verification. For optical-grade requirements, tell us the form and transmittance targets in advance.
How many sets can you build?
From one. Past roughly 15–20 sets vacuum casting is usually cheaper per unit, and we will say so rather than keep machining.
Need rapid prototyping? Send the drawing to an engineer.
First reply within 30 minutes during working hours (4 working hours at the latest); full quote and DFM feedback typically within 12 working hours.