There are times when the quantities of prototypes required rise well beyond the conventional 1 – 50 type range.

This may be due to the type of evaluation that is required, the number of people involved, or that they are really production items! Methods can vary but typically the greater the numbers, the closer the prototyping method gets to the production method. Pre-production cosmetic model

Vacuum Casting

Vacuum casting whilst requiring tooling, has specific attributes that makes it attractive to producing quantities of large or complex parts. Vacuum casting can emulate colour and texture in a variety of grades of polyurethane (PU) resin, both hard and flexible.

Additive Manufacturing (DLP)

Additive manufacture processes such as Digital Light Printing (DLP) that provides a highly detailed finish, can be applied very effectively to parts that will be moulded or machined, and can be produced in a fraction of the time.

There can often be several weeks to wait whilst injection mould tooling is being manufactured and this additive process is often used to produce the first few batches and bridge the gap. Production quality parts can even be delivered the same day!

Additive materials have also come on enormously in recent years allowing us to get as close as possible to end use materials. With production grade materials readily available, working parts can be ready to use from Day 1 of design sign off. Polypropylene, ABS, rubber and even flame-retardant parts can be replicated with a range of high-performance resins to suit a vast range of applications.Injection Moulded parts

Injection Moulding in Low Volumes

For injection moulded plastic parts, we now offer a range of tooling options, several of which move this process firmly into the pre- production arena. Lead-times can be competitive with vacuum casting and depending on quantities, price can be competitive as well. All with the significant upside of having prototypes in production intent materials!

By leveraging the speed and high-specification materials through additive manufacture alongside our moulding capability we can help you move seamlessly from sample parts to production.

Plunkett Associates have the added advantage of having additive manufacture and tooling and moulding engineers all under the same roof, so communication between all parties is easy and instant. We can often compress development timescales by validating tool design changes with production quality samples the same day.

Pre-production prototype modelCNC Machining

If the requirement is for metal components, these are frequently machined and post processed, as the production items would be, just in significantly shorter lead-times.

Under the pressure of time, CNC machining from solid will often offer advantages over casting and post machining, so long as the geometry permits.

Plunkett Associates provides a multitude of options to ensure you get the best possible from your pre production parts and can support you from initial prototypes through design approval/launch to subsequent tooling and production.

If you are in the early stages of your development project, please get in touch to find out how we can help you plan a smooth transition for your future production requirements.

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  • 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
  • “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
  • Thanks for the present that arrived this morning, as promised. Parts look first class, as always.
    Jon Todd, Design Manager, PHS Group
  • 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
  • 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
  • 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
  • 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
  • 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
  • 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
  • Plunkett Associates truly offer a complete turnkey solution with Speed, Effectiveness and Precision.
    David Harden, Director, Enica Ltd
  • 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
  • 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
  • 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
  • "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
  • “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
  • “Accuracy, finish and delivery all first class.”
    Andrew Peters, JMDA 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
  • "Tim's experience, expertise and supplier base have been fundamental to us getting this project off the ground."
    Sam Pearce, Jelly Products 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

Get in Touch with us for your Prototyping, Machining and Tooling & Moulding requirements…