Rapid Prototyping and Plastic Shop

The rapid prototyping center and experimental plastic shop provide a wide variety of prototype parts for development purposes. The services can be for one-off parts or short run prototype builds.

Rapid Prototyping Parts

With our rapid prototyping equipment, we are able to make prototype parts using various technologies. Materials include ABS, ABS-Plus, polycarbonate-ABS blend, nylon, and photopolymers. Some of the uses for these parts can be as design aids, packaging studies, assembly try-outs, concept development, or as master parts for mold making. The current technologies that we use are FDM (fused deposition modeling), stereolithography, laser sintering, and polyjet. We have a total of thirteen rapid prototyping machines so turn around times can be very quick.

Vacuum Casting Parts

Using the vacuum casting process, prototype urethane parts can be made with a wide range of durometers, from soft shore A to rigid shore D with gas resistant properties. This is excellent for making a variety of parts from hoses to support brackets. Some materials can be used in environments up to 260° F. We also can make clear or colored parts that are excellent for prototype lenses. The vacuum casting equipment has a large envelope size and there are three ovens to ensure good throughput.

Carbon Fiber and Epoxy Layup Parts

We take CATIA V4 or V5 data files, design the tooling, and then make fully trimmed carbon fiber or epoxy layup parts. We have three, 3-axis NC vertical milling centers that we use to cut the tooling from a variety of materials including twelve to sixty pound tooling boards, maple, mahogany, and other woods. The tooling is checked before the parts are made to ensure accuracy. The parts can be vacuum bagged or the infusion process can be used for excellent surface quality on both sides.

Vacuum Formed Parts

On our large vacuum forming machine, we can make fully trimmed parts from a variety of materials including ABS, polypropylene, polyethylene, PETG (clear), polycarbonate, and acrylic. We take CATIA V4 or V5 data files, design the tooling, mill the tooling, and make the parts. The vacuum forming machine has two separate tables for good throughput. We also have a programmable 5-axis trimmer that can be used for larger run orders.

Resin Transfer Parts

Using the resin transfer (injection) process, we are able to make large parts such as fascias and cowl screens. We have the capability of doing over-molds where multiple materials are used in the part. We design and mill the tooling and deliver fully trimmed parts.

Part Fabrication and Reworks

We offer bench built fabricated parts and we can also take existing parts and rework them as needed. We also take duplications from existing surfaces to create tooling. We have a large oven where we can make draped formed polycarbonate of acrylic parts to represent windshields and other glass surfaces.