Consumer Goods Prototypes

Advanced Manufacturing Techniques

We utilise a comprehensive suite of manufacturing technologies to meet your project’s unique needs, from initial concept validation to the production of final parts.

• Large Format SLA: Our large-format SLA (Stereolithography) machines are engineered for both scale and precision. They can print parts up to a metre in length in a single piece, eliminating the need for assembly and ensuring superior structural integrity. This technology allows us to capture the most intricate details on even the largest prototypes, from complex enclosures to full-scale automotive components.
• High-Performance FDM: Using high-performance thermoplastics like PEEK, PEKK, and carbon-fibre reinforced composites, our FDM (Fused Deposition Modeling) printers create prototypes with exceptional strength, heat resistance, and chemical stability. These materials are ideal for demanding applications where your prototype must perform under real-world conditions, simulating the properties of a final product.
• Precision CNC Machining: For parts requiring the tightest tolerances and specific material properties, our CNC (Computer Numerical Control) machining service provides a subtractive manufacturing solution. We can machine functional components from a wide variety of materials, including plastics, metals, and composites, ensuring your prototype meets exacting engineering standards.

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.

Vacuum Casting: Replication and Production Bridge

Vacuum casting is a vital process for creating high-fidelity replicas of your master prototype. Using a 3D printed master model, we create a silicone tool that can produce many identical parts. The process utilises two-part polyurethane resins that can be colour-matched and formulated to simulate the mechanical and aesthetic properties of end-use materials such as ABS, polycarbonate, and rubber. This method is perfect for low-volume production runs for market testing, trade shows, and pilot programs, providing a cost-effective alternative to expensive injection molding tooling.

Overmoulding and Threaded Inserts

To replicate complex assemblies and multi-material parts, we integrate advanced techniques directly into the prototype. Overmoulding allows us to create parts with a rigid core and a soft-touch outer layer, perfect for replicating grips and seals on consumer electronics. Additionally, we can embed threaded inserts into parts during the vacuum casting process, providing robust, metal-reinforced connection points that can withstand repeated assembly and disassembly.

Flawless Finishing

Our finishing department adds the final layer of realism to your prototypes. We offer a full range of services to transform raw parts into polished products. Techniques include sanding, polishing, and bead blasting for surface refinement. We also provide professional paint matching for flawless colour and texture application, as well as high-quality graphics and decals to replicate branding and user interface elements. This attention to detail ensures your prototype is visually indistinguishable from a finished product.

Order 3D Printed Parts

Getting a quote for your 3D printing project has never been easier. We offer three straightforward options to meet your needs.

Option One – Perfect for those seeking a swift and hassle-free 3D printing quote.

Option Two – If your project requires more than just printing, option two is your go-to choice, where we can provide quotes for CNC machining, surface finishing, vacuum forming, and vacuum casting for your 3D parts.

Option Three – For large, complex, intricate, or multi-part projects, look no further than option three. Give us a call, and our team will be more than happy to assist you in bringing your vision to life.

At Malcolm Nicholls Ltd, we make quoting fast, easy, and simple.