Frequently Asked Questions

How can you help me get my prototype made?

The word ‘prototype’ is confusing! We used to think this meant only 1 or 2 parts and could only be achieved economically through Additive Manufacturing processes. 

Today, however, that is certainly not the case and options are limitless and exciting!

We apply both additive manufacturing techniques and more conventional subtractive techniques to the direct manufacture or use tooling and moulding for a wide range of batch sizes where others fear to tread!Process choices

We appreciate there are more and more companies turning to online ordering systems to reduce staff overheads. It sounds great, upload your data and it’s possible for parts to be turned around in 24 hours, but this really is only applicable when a) you already have data, and b) you know exactly that this process is right for your geometry. What happens when you aren’t sure about either of the above or you have a complex part and simply need some advice?

This is where Plunkett Associates step in! Our expertise within the newest innovative processes and materials, access to a well trusted team of suppliers, along with our love of a challenge, allows us to be completely client driven rather than capacity directed, putting your needs at the top of our priority list.

Cost effective low volume production

Traditionally there has always been a huge gulf between prototyping and the other end of the scale, high volume production. At Plunkett Associates we pride ourselves in being able to bridge the gap, filling the void in the middle and are well able to provide both.

We have spent a great deal of time and effort to adapt various technologies to be more cost effective for low volume production quantities. The most significant of these is our work with injection mould tooling. 

Injection moulding as low as 20 off

Our Low Volume Production (LVP) tooling involves a hybrid of techniques with the exact configuration being customised to the client/geometry/quantities. The result is a mould tool that reflects the requirement and opens up an exciting option to produce high quality, yet low volume components.Low volume injection moulding 

As a result, we now injection mould on a regular basis from quantities as low as 20 and compete with the more common vacuum casting options at this price point.

Ensuring the design addresses the strength of the process

We also support ‘design for manufacture’. Ensuring that the design is optimised for the manufacturing route selected can be time consuming. 

We save you the hassle by working with a huge range of processes to ensure that the optimum solution is found and that the design addresses the strength of the process, rather than being at odds with it. 

Ultimately, we know we can help you! With a wide range of manufacturing options at our disposal we are well placed to highlight the different options based on differing quantities, so please give us a call.  

  • “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

Read more expert articles in our FAQ section where we discuss topics on materials, methods and products.

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  • “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
  • “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
    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
    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
    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
  • “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
    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
    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
    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
    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
  • “Thanks for the present that arrived this morning, as promised. Parts look first class, as always.”
    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
  • “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
    Jet Cooper, Sculptor