Need physical proof of your latest and greatest invention? Something you can present to management, a client, potential investors, or even just show off to your friends? Our rapid prototyping services can help. Drawing on our 3D printing capabilities, our efficient experts deliver punctual prototypes to your specifications.

If sections of different thicknesses are required, make the transition as smooth as possible using a chamfer or fillet. This will allow the material to flow more evenly through the mould.

Backed by in-house 3D CAD and industrial design proficiency, our custom prototyping services can accommodate differing levels of concept maturity. Whether you have full CAD files, a few sketches, or need help getting the idea on paper (then into a computerised format), we can convert your assets into production-ready files for plastic and metal component manufacturing.

When adding text choose embossed text over engraved text as it is more economical when creating the mould. Raising the text 0.5mm above the part surface will ensure the letters are easy to read.

The steps involved in prototyping may vary depending on the product or service being developed, but generally include the following:

When the interior of a part solidifies before its surface, a small recess in an otherwise flat surface may appear, called a sink mark.

Redesigning the part to remove undercuts or moving the part line can be possible solutions to make the design more feasible.

When designing ribs, use a thickness equal to 0.5 x the main thickness, define a height smaller than 3 x the rib thickness and use a base fillet with a radius greater than 1/4 x the rib thickness. Also make sure to add draft angle!

When only the highest-grade plastic prototype will do, or multiple prototypes are required for distribution to various stakeholders, it can be worth making a custom injection mould. Achieve near-perfect precision and repeatability with the most professional plastic prototyping method available.

Prototyping is important because it helps to identify potential issues in a product or service early in the development process. This can save time and money by allowing design flaws to be corrected before a final product is produced.

Trapped air in the mold can inhibit the flow of the material during injection, resulting in an incomplete part. Good design can improve the flowability of the melted plastic.

Here at UNSW we have 2 CR Clarke desktop injection moulders great for learning, testing and experimenting with the process!

Ready to step into the next dimension of plastic prototyping? Get in touch or book a meeting with our team to discuss your project.

Bosses consist of cylindrical projections with holes designed to receive screws and other fasteners and assembly hardware, they are very common in injection moulded parts as they are used as points of attachment or assembly.

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As the plastic shrinks, it applies pressure on the mold. During ejection, the walls of the part will slide and scrape against the mold, which can result to drag marks.

Thick sections can lead to various issues such as warping and sinking. Reducing the maximum thickness of the design can be achieved by making the thicker sections hollow is essential. To improve the strength of these sections, ribs can be used to create structures that are of equal strength and stiffness but with reduced wall thickness and weight.

Injection moulding typically produces parts with tolerances of +/- 0.25mm. Tighter tolerances can be possible in certain situations but increase the cost of manufacture dramatically.

When 2 flows meet, small hair-like discolorations may develop. These knit lines affect the parts aesthetics, but also they generally decrease the strength of the part.

We offer constructive feedback and innovative inputs because we think your prototype deserves no less! Our experience has gifted us unique insights into what works (and what doesn’t) in modern manufacturing, and we readily share these with you, while recognising your right to make the final call.

For interior edges, use a radius of at least 0.5 x the wall thickness. For exterior edges add a radius equal to the interior radius plus the wall thickness to ensure constant thickness everywhere. This can also help to stop stress concentrating in the sharp corners which can cause weaker parts.

Manage the demands of prototypes with metal parts with our prompt and precise CNC machining. Expertly automated to turn out metal components for instant assembly, or in combination with additional plastic parts as per your prototype’s requirements.

Establishing a prototype can be critical to your manufacturing project and demands speed and precision in equal measure. With comprehensive capabilities across plastic and metal component manufacturing, we’ll swiftly lay down building blocks for your success while ensuring quality control.

Commercially, injection moulding offers a flexible, consistent and cost-effective process of manufacturing that allows for rapid production of parts in a range of materials. Once the process has been set up and tested, machines can produce thousands of items per hour and once the mould is created (which is the most expensive element) the cost of production per component is relatively low.

Injection moulding is a manufacturing process that melts, injects and sets plastic into a metal mould. The plastics used by injection molding processes are relatively cheap and can be used to achieve a wide variety of properties, so injection molding is popular for creating many packaging and consumer products, like LEGO!

Undercuts refer to part features that cannot be manufactured with a simple 2-part mould because material is in the way while the mould opens or during the ejection of the part. Avoiding undercuts all together is usually the best options as they add cost, complexity and maintenance requirements to the mould.

It’s important to note that prototyping is an iterative process, and multiple rounds of testing and revisions may be necessary before a final product is produced.

The outer diameter of the boss should be 2x the nominal diameter of the screw or insert and its inner diameter equal to the diameter of the core of the screw.

Additionally, prototyping can help to communicate design concepts to stakeholders, such as investors, clients, or team members. It can also help to generate excitement and interest in a product, which can be important for marketing and fundraising efforts.

To avoid warping and sink marks on the part as the melted material cools down it is important to have uniform wall thicknesses and avoid thick sections if possible.

The uniform wall thickness limitations also applies to edges and corners; the transition must be as smooth as possible to ensure good material flow through the mould.

When certain sections cool (and as a result shrink) faster than others, then the part can permanently bend due to internal stresses.

When even the maximum recommended wall thickness is not enough to meet the functional requirements of a part, ribs can be used to improve the strength and stiffness of a part.

Add agility to your prototyping with this exciting additive manufacturing technology. Our advanced 3D printing services make ideas materialise before your eyes, efficiently and cost-effectively. In expert hands, 3D printers are ideal for producing NPI (new product information) models for products comprising plastic components, quickly delivering a prototype you can present, test, and refine.

Draft angle is a taper applied to the vertical walls of the component to be moulded to assist with releasing the part. Walls without draft angle may become stuck in the mould and will have drag marks on their surface.

Ready for a rapid assembly of your prototype that will progress your project to the next phase? Send us a message, give us a call, or arrange a time for an obligation-free consultation with an expert.