Frequently Asked Questions

What methods can I use to produce plastic prototype and production parts?

From 3D Printing to CNC Machining, Vacuum Casting to Injection Moulding, the process options for plastic parts are limitless. Transitioning from prototyping to production can be a challenge, and it may be worth considering the long term requirements (if you know them) first.Plastic Parts

Custom Prototyping

The decision making starts straightaway! With Stereolithography (SLA), Selective Laser Sintering (SLS), Multi jet Fusion (MJF) and Fused Deposition Modelling (FDM) there is considerable choice when prototyping custom plastic parts. 

However, with all the hype around 3D Printing techniques it is easy to overlook the other more established options, such as CNC Machining, which remains a very cost effective solution, especially for larger parts and functional materials. 

As quantities rise, tooling options are also most definitely worth considering, even for surprisingly low numbers. 

Transitioning from Prototyping to Production

Transitioning from prototyping to production quantities can be a challenge, and rather than automatically jumping to additive manufacture for first prototypes, it is worth considering the long term requirements (if you know them) as this may have a bearing on your process choices.

Design for manufacture is vital and applicable to all processes, despite the hype that 3D Printing can do anything! The catch is that features get designed in that either prohibit conventional manufacture or make it unnecessarily expensive.Plastic Parts

Low Volume Production Plastic Parts

Rapid Prototyping (RP) is ideally suited to handling high component complexity. It provides a fast and economic means of validating such designs before tooling release. 

However, despite the growth of RP, CNC Machining still plays a significant part in plastic custom prototyping and low volume production and should not be overlooked as a viable option. Material choices are wider and when combined with our global sourcing, the results we can give you are often extremely economically attractive.

Vacuum Casting is the first step into tooling; this process offers good part detail, which along with a range of polyurethane material options, provides an easy, cost effective transition into the production of plastic parts. Depending on the part geometry and material choice, tool life is typically 15 - 25 off.

Injection Moulding

Ultimately, Injection Moulding still dominates the production of the majority of plastic parts, and whether combined with bridge tooling or full production tooling, offers a consistent high quality source of parts. Plastic parts

Usually considered to involve long lead times and high costs, this is not always the case and is really a case of matching the requirements to the type of tooling produced. Moulding a handful of parts is very different from 100,000 parts but as specialists in low volume quantities, this is something we can help you with.

So why would you consider injection moulding to make just a handful of parts? There are several answers, but the ones we come across most frequently relate to materials. It delivers the production intent material and, once the tooling is in place, parts are available quickly and at low cost. 

As an ISO:9001:2015 Quality System certified supplier, we have the knowledge and experience to supply the perfect solution for your plastic parts across all quantities.

  • “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