Injection mould tooling for low volume production parts.
Initial SLS prototypes for testing in only a few days.
After the success of their first project with Plunkett Associates, Kirintec got back in touch with a request for assistance developing another reel concept.
Kirintec were buying an ‘off the shelf’ reel, which although satisfactory, lacked the ergonomics and branding they required. Quantities had been low (10-20) but were increasing to around 1500. Kirintec decided it was time to develop their own manufacturing solution that would be more suited to their needs.
The new design had to support the following requirements:
The project deadline was critical. In order to supply a wound product to their customer, Plunkett Associates had only 6 weeks from receipt of order to get the parts designed, manufactured, assembled and delivered to the winders.
A concept of interchangeable parts, which allowed individually sized reels to be made up according to requirements, was the ideal solution.
The assembly process was paramount to the success of the project and so initial prototypes to check form and fit were carried out through Selective Laser Sintering.
The reel stocks were CNC machined in 2 different lengths and of a standard diameter to allow fitting onto automated machinery for a faster winding process. The turning handles were also CNC machined.
Flat end pieces, suitable for both stock sizes, were injection moulded and embossed with Kirintec’s logo.
Carrying handles were also injection moulded using an interchangeable insert in the tool, which allowed the one tool to mould two sizes of handle suitable for the 2 different reel stocks. This helped to reduce tool costs.
The bulk of the assembly was carried out by Plunkett Associates. The reels were then sent to the winders with a kit of 3 parts making the final assembly of adding the carry handle straightforward. The fully loaded reels were then delivered to Kirintec within the deadline.
Kirintec were delighted with the outcome; not only do they now have two reel options with improved functionality and aesthetics, but also have the advantage of a significant cost reduction over the product they were previously purchasing.
“Plunkett were equally creative and responsive during the design and development phase as well as product manufacture and fulfilled multiple delivery dates on time, every time…
It is refreshing to work with such a talented and customer focused team and I would like to thank Julian for his attention to detail throughout.”
Nigel Whitman, Operations Manager
“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
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
“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
"Tim's experience, expertise and supplier base have been fundamental to us getting this project off the ground."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
“Accuracy, finish and delivery all first class.”Andrew Peters, JMDA Ltd
“We use Plunkett Associates because we want someone we can trust, that knows what they’re talking about, has all the contacts, will provide reliable advice and feedback and will get the right result for us.”Jim Copestick. Design Manager, Thorlux Lighting
“We always know exactly what we’re getting and we know we won’t be let down on quality, price or lead times.”Mark Williams, Research and Development Director, Johnson Safety Products
“Plunkett Associates truly offer a complete turnkey solution with Speed, Effectiveness and Precision.”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
“Thanks to Plunkett Associates flexible, bespoke and cost effective service I was able to produce the objects that I had originally had in mind.”Simon Ryder, Artist
To create such a consistent quality finish in chrome was an amazing achievement and the prototypes really gave our stand the wow factor.James Clark, Group Commercial Director, The Airdri Group
Interestingly, people who look at it in its own right with little knowledge of what it does, just like it! It’s tactile and it looks good…Tim Collings, Operations Director, Troika Systems Ltd
"With their simple to understand language, willingness to go the extra mile and approachability, Plunkett Associates were a great partner for our company. We couldn’t be happier with the results of our project. (A working prototype that they got right first time, by the way). Thank you!"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
“Thanks for the present that arrived this morning, as promised. Parts look first class, as always.”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
“ 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
“Doing business with you has been an absolute pleasure. You have made my goals a reality. You have been patient, helpful and above all, responsive. Best service that I have experienced in ages. I consider Plunkett Associates to be an integral part of my business plan moving forward.”Jet Cooper, Sculptor
The benefits of CNC parts include substantial flexibility in material choice, high accuracy and repeatability.
Selective Laser Sintering (SLS) is the second most commonly used process after Stereolithography (SLA). SLS parts can be produced with high functionality in very short lead times.
Produces production intent material properties. Injection Moulding is used for development as well as production parts.