Precision to Production: CNC Machining
At Malcolm Nicholls Ltd (MNL), we don’t just offer manufacturing services we deliver a cohesive, end-to-end solution for product development, from initial prototype to low-volume production. By seamlessly integrating state-of-the-art CNC Machining, cutting-edge FDM 3D Printing, and versatile Vacuum Casting, we provide the ultimate recipe for speed, precision, and material fidelity.
UK-based CNC Machining
Over 50 years of expertise
Custom parts delivered in days
What We Offer
Precision CNC Machining
Unmatched Accuracy: Utilising 5-axis milling and 11-axis turning to achieve complex geometries and ultra-tight tolerances in both metals and engineering plastics.
Material Versatility: We machine production-grade materials, including Aluminium, Stainless Steel, Titanium, ABS, Acetal, and Polycarbonate.
Volume Flexibility: Ideal for high-precision prototypes and low-volume production runs up to 1,000+ parts.
High-Performance FDM (3D Printing)
Engineering-Grade Materials: Specialising in High-Temperature FDM using polymers like PEEK, ULTEM™ (PEI), and Carbon-Fibre Nylons.
Functional Components: Perfect for parts requiring extreme heat resistance, high strength, chemical inertness, and flame retardancy (e.g., aerospace, motorsports).
Design Freedom: Build complex, internal features and lattice structures impossible with traditional machining.
High-Fidelity Vacuum Casting
Cost-Effective Replication: Produce small batches (up to 25 copies) from a single silicone tool with the quality of injection moulding.
Production-Matched Resins: Cast parts in materials that simulate the properties of ABS, PP, PC, and various elastomers (rubbers) for realistic testing.
Rapid Turnaround: Significantly faster and cheaper than setting up hard tooling for initial market tests and pilot runs.
Integrated Hybrid Solutions
Optimised Workflows: We strategically combine CNC, FDM, and Vacuum Casting to leverage the best of each technology for speed, accuracy, and cost efficiency.
Component Perfection: Use CNC for critical interfaces, FDM for complex features, and Casting for replication—all within one project.
Consultancy-Led: Our consultants advise the most efficient manufacturing path to move your design from concept to robust, functional product.
CNC Machining: Unmatched Precision and Robust Performance
CNC machining remains a cornerstone of precision engineering, and our capabilities are designed to meet the most demanding specifications across industries like Automotive, Aerospace, and Motorsport.
Core CNC Capabilities
Multi-Axis Milling: Our advanced 3-axis and 5-axis milling centers allow for the creation of complex geometries and tight-tolerance components. This process is ideal for parts requiring extreme accuracy and superior surface finish.
Multi-Axis Turning: With capabilities up to 11 axies, our turning services are perfect for intricate, rotational components, ensuring high-volume, high-precision results for cylindrical parts.
Low-Volume Production: We excel in delivering anything from a single, bespoke item to low-volume runs of up to 1,000+ parts, bridging the gap between prototype and mass production without the need for expensive tooling
Material Expertise
We machine a vast array of materials, including:
Metals: Aluminum, Stainless Steel, Titanium, Copper, Brass, Steel, Sterling Silver, Bronze, and high-performance alloys.
Engineering Plastics: ABS, Acetal, Nylon, Polycarbonate, PTFE, PEEK, PVC, and other hard plastics chosen for their mechanical and thermal properties.
The Malcolm Nicholls Advantage: Manufacturing Without Compromise
In today’s accelerated product development cycle, you shouldn’t have to choose between precision, material performance, and production speed.
At Malcolm Nicholls Ltd (MNL), we have strategically integrated three foundational manufacturing technologies CNC Machining, High-Temperature FDM, and Vacuum Casting to deliver the ultimate solution from initial prototype to low-volume production. We are experts in hybrid workflows, ensuring that whether your project demands sub-0.05mm tolerances in metal, aerospace-grade thermal stability in polymer, or cost-effective replication of small batches, MNL provides the perfect, unified manufacturing recipe. Our goal is to empower engineers and designers to innovate without being constrained by conventional manufacturing limits.
The Ultimate Prototyping Recipe: Integrated Hybrid Solutions
We don’t just offer manufacturing services; we engineer the most efficient path to your final product. The true strength of Malcolm Nicholls Ltd lies in our ability to seamlessly combine our technologies to deliver optimal results, eliminating the need to compromise on complexity, accuracy, or material performance.
Integrated Hybrid Workflows: Combining the Best of All Worlds
| Hybrid Workflow | Primary Technologies | Core Application & Goal | Key Benefit |
| CNC & FDM Hybrid | CNC Machining & FDM 3D Printing | Creating assemblies that require both structural integrity (metal components) and complex geometry (polymer enclosures/structures). | Strength Meets Complexity: CNC provides robust mounting points; FDM delivers design freedom and lightweight structures. |
| CNC & FDM Precision Finishing | CNC Machining & FDM High-Temp Polymers | Achieving ultra-tight fits and critical surface finishes on 3D printed engineering polymers (e.g. PEEK, ULTEM™). | Guaranteed Critical Fits: CNC ensures features like boreholes and mating faces achieve sub-0.05mm tolerances for perfect assembly. |
| CNC & Casting Synergy | CNC Machining & Vacuum Casting | Creating master patterns for casting that require the highest level of precision and an exceptionally smooth surface finish. | High-Fidelity Replication: Guarantees a flawless master model, leading to high-quality, repeatable results in production-grade resins. |
| SLS & Casting Integration | SLS 3D Printing & Vacuum Casting | Utilising durable, dimensionally stable SLS Nylon parts as robust master patterns for silicone tooling. | Durable Master Patterns: Ideal for complex geometries; SLS provides excellent mechanical properties for repeated use in the casting process. |
The Ultimate Outcome: Manufacturing Without Compromise
This integrated approach ensures that your final product benefits from the precision and material strength of CNC, the design freedom and advanced materials of FDM and SLS, and the cost-effective, high-fidelity replication of Vacuum Casting. We eliminate the need for compromise, delivering a robust, accurate, and truly functional final component, fast.
Full-Service Capabilities
Our in-house team and trusted UK partners allow us to deliver at speed and scale. We combine traditional craftsmanship with cutting-edge production methods, including:
SLA
Stereolithography (SLA) Utilising two of the UK’s largest SLA 3D printers, and a suite of machines. We produce high-precision, large-format automotive components with exceptional surface finishes, ideal for both prototyping and end-use applications.SLS
Employing SLS technology to create durable, high-tolerance parts suitable for functional testing and low-volume production, meeting the rigorous demands of the automotive industryFDM
Delivering robust and cost-effective automotive prototypes and components, facilitating efficient design validation and testing processesLarge Format
Large format 3D printing service, utilising our large format SLA 3D printers with their impressive build platforms of 800 x 800 x 600mm.Transparent
We can produce large transparent 3D printing without the need for sectioning and fabricating back together, by utilising our large format SLA 3D printers.Carbon
Carbon has proven itself for its reliability in the toughest of environments, whether your looking to use it in low volume production or rapid prototyping Carbon 3D Printing is a great option.Vacuum Casting
Our vacuum casting capabilities enable the production of high-quality, low-volume components that closely mimic final production parts, supporting seamless transitions from prototyping to manufacturingCNC
With advanced 5-axis CNC machining, We manufacture precise metal and plastic automotive parts, ensuring high accuracy and superior surface finishes for both prototypes and production components. RIM
Reaction Injection Moulding (RIM) utilising RIM to produce lightweight, impact-resistant automotive components, offering a cost-effective solution for low-volume production runs.High-Temperature FDM:
Engineering-Grade Additive Manufacturing
Our Fused Deposition Modeling (FDM) service goes beyond simple plastic prototypes, leveraging high-temp, high-performance engineering-grade thermoplastics for true functional parts. This capability is perfect for applications requiring strength, chemical resistance, and thermal stability.
High-Performance FDM Materials
We specialise in materials that deliver production-level performance:
| Material Family | Key Examples | Core Benefits | Typical Applications |
| PEEK / PEKK | ThermaX™ PEEK, CarbonX™ PEEK+CF | Exceptional heat, chemical, and mechanical resistance, low smoke/toxic gas emissions. | Aerospace components, high-temperature jigs/fixtures, down-hole parts. |
| PEI (ULTEM™) | ULTEM™ 9085, ESSENTIUM 9085 | Aerospace-grade strength, thermal stability, and inherent flame resistance (UL94 V-0). | Electrical housings, interior aircraft components, demanding structural parts. |
| Carbon-Fibre Nylons | CarbonX™ PA12+CF, Essentium HTN CF25 | High-strength, low-warp, excellent stiffness, and light weight. | Jigs, fixtures, lightweight structural components, durable functional prototypes. |
| Polycarbonate (PC) | 3DXMAX® PC, CarbonX™ PC+CF | High-strength and heat-resistant (Tg 147°C) for durable applications. | Functional prototypes, protective housings, tooling |
Securing Your 3D Printing Project with an NDA
We understand the sensitivity of your projects and operate with the utmost confidentiality. Strict adherence to non-disclosure agreements (NDAs) is ingrained in our company culture. We’re happy to work within your NDA framework and are prepared to sign mutual agreements to ensure your intellectual property remains safeguarded. Trust and transparency are cornerstones of our business, and we’re committed to partnering with you with complete peace of mind.
The Synergy of Technologies: Vacuum Casting and Hybrid Solutions
At MNL, the power of our service lies in combining these processes to offer the most efficient and accurate solution.
Vacuum Casting: High-Fidelity Replication
Vacuum casting is the ideal method for producing small batches (typically up to 20-25 copies per mould) of high-quality, high-fidelity parts with properties that closely match final production materials.
- The Process: We create an ultra-accurate SLA 3D-printed master model which is then used to form a flexible silicone tool. Polyurethane (PU) resins are then cast in a vacuum to eliminate air bubbles and ensure perfect detail replication.
- Production-Matched Materials: Our resins can closely simulate the properties of production plastics like ABS, PP, Nylon, PC, and elastomers (rubber-like parts from 20A to 95A Shore hardness). We also offer transparent, high-temperature, and flame-retardant options.
- Key Benefits: Low-cost tooling compared to injection moulding, fast turnaround, excellent surface finish, and ability to incorporate features like threaded inserts and overmoulding for seals and gaskets.
The Ultimate Prototyping Recipe
