Aluminium tooling and fast track injection moulded parts for life saving PPE

Fast Track Injection Moulding - running 3,000 parts a day JUST 4 DAYS FROM DESIGN SIGN OFF!

Design for Manufacture critical in moving from 3D printing low volumes to injection moulding and increased production quantities

With the current urgent requirement for PPE by all healthcare sectors, we were approached by Resource 12 regarding the production of single use visors. They had a design that was currently being 3D printed however there was a need to scale up production.

Plunkett Associates was tasked with adapting the design to make it suitable for injection moulding with the aim going forwards to manufacture two aluminium single cavity tools and a full production twin cavity steel tool.PPE Face Shield 

Prototypes were made to check form and fit, and a single cavity tool was trialled to test the material and mould.  

4 days from design sign off and we are running at 3,000 parts a day with a view to producing over 70,000 parts a week once the subsequent tools are operational.  

Parts are shipped to Resource R12 for assembly before being sent out to those most in need and the process of gaining CE accreditation to ensure the visors are of the best possible standard is also underway.

We are delighted to say the project is proving to be a huge success, with moulding well able to support the capacity for high volume production. 

Update 1: 100,000 PPE Visors shipped for NHS and Healthcare Workers!

It’s been just 2 weeks since we first started supplying PPE visors to our client, Resource-12, and we are delighted to report that, to date, we have shipped 100,000 for distribution across the Healthcare sector. Aluminium Tooling

Resource-12 has manufactured the face visors in accordance with BS EN 166:2002 for supply to the NHS/healthcare workers.

Initially our toolroom produced 2 aluminium single cavity tools to get things up and running, followed by a double cavity steel tool which was brought online last week.

With 3 tools in the presses, our mould shop has been busy! Running 24/7 has allowed time for a couple of mods to the tools and means going forwards we have the potential for up to 16,000 parts a day, circa 100,000 a week. 

Those of you who know us, know that we are used to tight timescales and getting things done above and beyond the ‘norm’!

However, to have achieved these quantities in these timescales with the current COVID-19 restrictions has been something of a different challenge! PPE Face Shield

It’s been a huge team effort and we are grateful to everyone who has been involved in making it happen.

Update 2: CE Mark Approval for Face Visor in Record Time!

Plunkett Associates are proud to be helping companies bring products to market. 

  • “Plunkett Associates have excellent breadth of experience, work with high quality partners and have a flexibility that we have found enables challenges to be met successfully, cost effectively and in a timely manner.”
    Nick Skaer, CEO, Orthox Ltd
    Nick Skaer, CEO, Orthox Ltd
  • Plunkett associates always find a solution. Whatever we need to prototype, they have a great grasp on the technologies available, costs and lead-times so we get the right solution tailored to the project needs. Have always delivered and never let us down.
    Naim Audio
    Naim Audio
  • “I can’t recommend Tim and his team highly enough. We ended up with a design which can be produced and assembled quickly, efficiently and reliably, in volumes that make sense”
    Simon Leggett, Director, Olivewood Technology
    Simon Leggett, Director,  Olivewood Technology
  • "Tim's experience, expertise and supplier base have been fundamental to us getting this project off the ground."
    Sam Pearce, Jelly Products Ltd
    Sam Pearce, Jelly Products Ltd
  • “We were really surprised at how quickly they turned round such a high quality prototype and the parts certainly proved their worth. They were of high enough quality to provide a fantastic visual representation and to undergo rigorous testing."
    Stuart Wilson, Design Director, TRT Lighting
    Stuart Wilson, Design Director, TRT Lighting
  • “Accuracy, finish and delivery all first class.”
    Andrew Peters, JMDA Ltd
    Andrew Peters, JMDA Ltd
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    Jim Copestick. Design Manager, Thorlux Lighting
    Jim Copestick. Design Manager, Thorlux Lighting
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    Mark Williams, Research and Development Director, Johnson Safety Products
    Mark Williams, Research and Development Director, Johnson Safety Products
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    David Harden, Director, Enica Ltd
    David Harden, Director, Enica Ltd
  • “Kirintec were thrilled with Plunketts. They made a complex process simple and we were just amazed at the lead times achieved. Plus, every single deadline was met without any drama.”
    Penny While, Marketing Director, Kirintec
    Penny While, Marketing Director, Kirintec
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    Simon Ryder, Artist
    Simon Ryder, Artist
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    James Clark, Group Commercial Director, The Airdri Group
    James Clark, Group Commercial Director, The Airdri Group
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    Tim Collings, Operations Director, Troika Systems Ltd
    Tim Collings, Operations Director, Troika Systems Ltd
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    Carolina Ballon-Forrester, Director, Kittyrama Ltd
    Carolina Ballon-Forrester, Director, Kittyrama Ltd
  • Plunkett Associates worked on the design and production of titanium frames for an artificial heart valve where precision and consistency was paramount. Communications were efficient and productive with concepts readily incorporated into the final design, and suggestions for improvements all highly appropriate. The quality of the end product was ideal and I have no doubt that I will use the advice and expertise of Plunkett Associates again.
    David Wheatley, Wheatley Research Ltd
    David Wheatley, Wheatley Research Ltd
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    Jon Todd, Design Manager, PHS Group
    Jon Todd, Design Manager, PHS Group
  • “Plunkett Associates have a fantastic supply chain, work with all sorts of production processes and will always do their utmost to solve a problem.”
    Naim Audio
    Naim Audio
  • “ Plunketts developed a solution that met our precision requirements at a cost significantly lower than alternative manufacturing approaches we had investigated”
    Nick Skaer, CEO, Orthox Ltd
    Nick Skaer, CEO, Orthox Ltd
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    Jet Cooper, Sculptor
    Jet Cooper, Sculptor