Our extensive experience in industrial design allows us to work closely with clients to convert concepts into cost effective products.

Nearly all prototyping is carried out on the premises, including pattern and mold making. This enables us to maintain control of the schedule and the quality of work. A prototype is produced for every new job enabling features to be tested and amendments made before starting final production.

Some items can be fabricated without vacuum forming by simply folding one or more pieces of flat plastic sheet and assembling to create a three dimensional object. This process involves cutting, routing, drilling and assembly. This type of fabrication is ideally suited smaller runs of between 10 and 1,000 units. The tooling requirements for this process are minimal.

Vacuum Forming is a thermoforming technique for shaping flat plastic into a three dimensional shape by heating the sheet until flexible and then withdrawing air from between the heated sheet and a mold. It is an automated process that is well suited to medium volume production runs of between about 100 and 100,000 units. Tooling charges are much lower than injection molding due to the reduced complexity and much lower loads. A production run using vacuum forming can be set up with several molds on the same machine bed to form multiple impressions. This greatly reduces machine time and material costs. Depending on the time, budget and finish required production tools or molds can be made from epoxy or polyester resin, cast or milled aluminium and even wood.

Acrylic (Perspex) – Transparent plastic commonly used for simple fabricated display holders and stands.

High Impact Polystyrene – Commonly used for vacuum formed display stands or covers. Many bright and high gloss finishes are available.

ABS – Used for vacuum formed housings and enclosures for machinery.

Polycarbonate – Transparent material used for vacuum formed housings and enclosures that require extremely high toughness.

PVC – Used for a wide variety of different applications. Coloured finishes available.

PETG (Polyester) – Transparent material used for vacuum forming and fabrications that require both clarity and strength.

Polypropylene and polyethylene – Properties are very similar and generally suit the same production methods. Robust materials ideally suited for the production of machine goods. Suitable for low and high temperatures. Good for exterior use.