Razor Handles Including Intricate Features and Over Mouldings We Can Over Mould onto Virtually Any Substrate Vacuum Cast Materials In a Variety of Colours including Clear and Tinted Overmoulded Flash is Controlled using Bespoke Techniques Flexible Over Mouldings can be trialed in Many Different Shore Hardness's
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Razor Handles

Certain projects have been selected from MNL’s Rich History, this one comes from 2008:

First launched in 2008, the Azor 4-Blade System Razor from King of Shaves was the first British designed system razor for over 100 years. The unique flexible hinge “shaves better because it bends” – it incorporates a patented Bendology.

At the same time, the large soft rubber ‘beard bumper’ helps reduce risk of unwanted nicks and lifts stubble for a smoother more comfortable shave. The ergonomically designed, lightweight handle allows for a superbly comfortable shave which effortlessly follows every contour and curve of your face.

Malcolm Nicholls Limited (MNL); having prototyped many ladies and gents shaving products, were approached in this instance to produce a gentleman’s razor. The Azor was produced using the following key processes. 3D printed models utilising MNL’s high resolution Stereolithography (SLA) process. This process gives the best surface finish and a defined crispness of feature on a component. Once all of the components were produced via 3D printing, they were hand finished by MNL’s highly skilled model making team. Predominantly most components were finished to a perfect gloss; others that were going to be cast as elastomers only required a satin finish. Once all components were finished to their required level, they were then used as patterns to aid the creation of a silicone soft tool.

Castings from a silicone tool are produced in a variety of polyurethane (PU) materials;  The PU materials chosen mimicked the production intent material, including elastomers and rigids alike.  Prototypes were colour matched to Pantone references supplied, and to sample parts for texture.

A wide range of razors have been created by MNL using similar processes as mentioned above. Some using plastic and some in metal, a wide variety with elastomer over-mouldings.

Ladies disposable razor handle. This set of parts were required to be identical in their semi-transparency colour, perfectly edge-matched over-moulding and accurate to provide a perfect snap fit to the production made razor heads.

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