Prototype Projects Ltd

Prototype Projects, established in 1980, is a specialist in the manufacture of prototypes. The company is experienced in 3D Printing, CNC Machining, Rapid Prototyping, Model Making and Additive Manufacturing. The company is located in Royston, Hertfordshire.

As a leading prototyping company, we provide a completely integrated in-house service including model making, rapid prototyping, 3D printing, CNC machining, finishing and additive manufacturing of production parts.

We are well known for our fast turnaround times, from quote through to dispatch. We offer Express services on 3D Printing (next day dispatch) and CNC Machining (3-day dispatch).

Our 3D Printing Suite is equipped with SLS, SLA, FDM, Polyjet and Figure 4 machines. We are also able to offer texturing (SLS & SLA) and dyeing (SLS) as part of our range of finishing options.

Our CNC Machining department is fully equipped and we can mill or turn in both metals and plastics.

We also offer Model Making services, as well as Vacuum Casting and Laser Cutting, all from our bureau in Royston.

Products and services

Model Making

Professional model making is the fusion of skills, techniques and technologies to produce high-quality 3D representations of objects. These might be for presentations, design verification, functional production testing or architectural presentations. Model making is ideal when automated prototyping technologies or processes are not enough – perhaps due to size or complexity – or where the model needs to incorporate parts produced by different means.  

Vacuum Casting

Vacuum casting in polyurethane is quick, versatile and cost-effective for producing small quantities of high-quality, detailed parts. These typically simulate parts injection moulded from engineering plastics or thermoplastic elastomer (TPE) materials. Vacuum casting is also ideal for overmoulding. Vacuum casting is suitable for prototype and end-use parts. It can be used for concept models, visual models, pre-production prototypes, functional test prototypes, models for thermal and airflow testing, and for assembly line trials.

CNC machining: milling and turning

CNC machining is versatile for producing prototype parts in metals, alloys and engineering plastics. Typically, we CNC machine parts that will be manufactured by other processes once they are in mass-production. In addition, we CNC machine one-off final parts and small batches for special-purpose machine builders and manufacturers of low-volume, high-value products.

3D Printing: Stereolithography (SLA)

Stereolithography (SLA rapid prototyping) is a 3D Printing technology used for rapid prototyping and additive manufacturing.SLA prototyping is one of the most popular and versatile technologies offered by Prototype Projects and can be used to produce concept models, one-off presentation models and masters for use in Vacuum Casting. Prototype Projects operates a suite of SLA rapid prototyping machines (one of which is dedicated to medical device prototyping) working round the clock, giving us the capacity to produce parts quickly and cost effectively with no compromise on build quality. SLA prototyping is a 3D printing process used in rapid prototyping, and is typically used early in the product development process as concept or one-off presentation models and masters.It produces parts with good quality smooth surface finish, excellent optical clarity, high accuracy and thin, straight, vertical walls.

3D Printing: Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS) is a 3D Printing technology used for rapid prototyping and additive manufacturing of 3D parts with complex shapes and geometries. A wide of range of part sizes is possible with SLS, with a choice of finishing and turnaround options available to suit most requirements. Prototype Projects offers SLS services on our Formiga P110 LS machine, manufactured by EOS GmbH. The Formiga P110 Laser Sintering machine is among the most technically advanced and versatile plastic 3D Printing and additive manufacturing machines in the world. The SLS process can be used to produce parts that closely mimic the properties of finished parts, particularly where high degrees of accuracy are required.This high level of accuracy makes SLS an ideal choice for all stages of the production process from concept model through to presentation and testing models.

3D Printing: Polyjet

PolyJet is a 3D printing process which is used for rapid prototyping and additive manufacturing.The PolyJet 3D printing process is unique among 3D printing technologies for its range of complex printers which are capable using multiple materials simultaneously to build a single part. Our PolyJet 3D printing service is a highly versatile process and offers a cost-effective and fast way to achieve aesthetically appealing prototype parts, at pre-production stage. PolyJet 3D printing is also ideal for short-run additive manufacturing of production parts. PolyJet is ideal for 3D parts where more than one material will be required. Examples include parts where an outer layer of softer, more flexible material is needed. These layers can be ‘overprinted’ in different materials to give a range of properties, features, thicknesses and harnesses.

3D Printing: Digital Light Projection (DLP)

Digital Light Projection is a 3D-printing technology which is ideal for functional prototyping and very low volume production. It delivers an ultra-high print speed along with quality and accuracy meaning we can print your prototypes quickly while maintaining quality and accuracy. It is ideal for: functional prototyping and concept models, investment casting jewellery patterns, end-use durable plastic parts, jigs & fixtures and moulds & master patterns.

3D Printing: Fused Deposition Modelling (FDM)

We offer Fused Deposition Modelling (FDM) prototyping for low-cost production of small numbers of strong, durable prototype parts, jigs and fixture assemblies from ABS-M30. FDM parts can be used as early concept prototypes, to validate design and for functional testing of specific properties e.g. heat resistance, durability and strength. FDM parts can be produced to represent the strength, flexibility and durability properties of the final production part and are ideal for physical testing.

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