Design Consideratons.

Do you have sketches or 3D models. We can help with the design of any product and get your ideas down onto "paper" or should we say3D CAD models. There are 3 main stages

1. We will sign an NDA (Non Disclosure Agreement) so that you can be assured that your project details are kept secure.

2. We then discuss the project with you and depending on your budget and how far you have already got, offer a number of solutions for CAD data and or physical modelling. At this stage we discuss product requirements, material requirements, end use, tool requirements, route to market if required, packaging and distribution.

3. CAD modelling is commissioned and once approved we move to step 4

4. Once budget and timescales are agreed for the Cad work, we will then use the CAD models to get the best price for prototypes, tooling, hard or soft, depending on the project requirements, or if needed, source machined parts to your requirements.

The choice in prototypes is usually based on a number of constraints from any combination of timescales, cost, finishing, and physical behaviour of the model.

   * Photo-realistic rendering - CAD models or movies showing  interaction with other modelled parts

   * Hand made models using traditional modeling methods 

   * Aluminium-filled cast epoxy resin

CAD derived prototypes

   * DMLS - Direct metal laser sintering

   * CNC - high speed machining – primarily in aluminium, plastics, foams & woods

   * Stereolithography (SLA) – for high accuracy and good surface  finish using plastic mimic resins from ABS to Water Clear Acrylic
     - fairly brittle.

   * Selective Laser Sintering (SLS) – produces stonger parts from a wide range of commercially available powder materials -
     nylons & glass filled nylons

   * Stratasys FDM (Fused Deposition Modelling - ABS, Polycarbonates & polyphenylsulfones) – commonly used within engineering design

   * Objet- 3D ‘printing’ in acrylic

   * Thermojet - wax block models

   * Mcor glued paper based models - extremely cheap material used to produce models - more for visual looks than functionality

   * Vacuum casting using silicone rubber as a tooling medium, polyurethane parts that can range from hard like ABS, soft like
     TPE's, or clear like Acrylics.

Rapid Prototype tooling, usually with a MUD bolster or aluminium bolster set

   * DMLS (Direct Metal Laser Sintering) - for mould tools/inserts

   * Alumide (Sintered aluminium / nylon) - for mould tools/inserts

   * Aluminium-filled cast epoxy resin

   * CNC - high speed machining – primarily in aluminium

The rapid SLA / SLS / FDM / Objet - 3D methods usually give the quickest turn around for look and feel models.

For more exact component matches for testing of functionality in a real world environment, then one usually needs to look down the rapid protype tooling inserts route or machining parts from sold blocks of resin, although SLS and FDM might be an option.