The highly acclaimed VX220 from Vauxhall was developed under a joint arrangement with Lotus Engineering. Malcolm Nicholls Limited (MNL) role in this development was to provide prototypes of the seals for the removable roof section, door mirrors, doors etc.
The extremely complex curvature of the seals made them an ideal candidate for the 3D printing via Stereolithography (SLA) process. The 3D printed models were used as masters to produce silicon tooling and subsequent vacuum casting in a polyurethane material that emulates most shore ratings of elastomer. From this tool 50 castings were produced.
The vehicles used for the TV advertisements were all adorned with MNL prototype seal parts.