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Prototype to Production: What Changes when Scaling a Mechanical Design

Explains how designs evolve from one-off prototypes to repeatable production. Covers tolerance strategy, material substitutions, tooling considerations, QA requirements, and documentation changes.
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Material Capabilities

Materials We Work With

Material certificates available upon request.

Metals

  • Aluminium 6061, 7075 and other common grades
  • Stainless steel 304, 316
  • Mild and carbon steels
  • Brass and copper alloys

Plastics

  • ABS, Nylon, POM/Delrin
  • Polycarbonate, Acrylic
  • Engineering plastics for higher performance applications

3D Printing Materials

  • Photopolymer resins
  • Nylon and composite powders
  • Standard FDM filaments

Sheet & Plate Materials

  • Photopolymer resins
  • Nylon and composite powders
  • Standard FDM filaments

Casting Alloys

  • Aluminium A356, A380 & other common alloys
  • Zinc alloys

-Magnesium alloys

Composites

  • Carbon fibre laminates
  • Glass-fibre reinforced plastics
  • Structural composite sandwich panels
  • Moulded and machined options available

Surface Finishes & Treatments

  • Anodising & hard anodising
  • Powder coating
  • Plating (zinc & nickel)
  • Heat treatment
  • Bead blasting & polishing
Supported File Formats

CAD & File Formats We Accept

You can upload design data in most common engineering formats. Our secure upload system supports files up to 100MB for quoting and DFM review.

  1. STEP (.step, .stp)
  2. IGES (.igs, .iges)
  3. STL (.stl)
  4. DXF / DWG for 2D profiles
  5. PDF drawings
  6. Compressed ZIP folders for multiple files
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QUALITY & INSPECTION

Quality Control You Can Rely On

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  • Dimensional inspection on each batch
  • Optional detailed reports for critical components
  • Material certificates available where required
  • First Article Inspection (FAI) for new tooling or production runs
  • Traceability for repeat and production orders
COMPONENTS

Components We Manufacture

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  • Mounting brackets and structural plates
  • Housings, covers and enclosures
  • Shafts, pins and bushings
  • Fixtures and jigs for production
  • Custom tooling components
  • Prototype assemblies and test rigs