Our customer was interested in creating several modifications of the same chemically etched component, the difference between each part was negligible, but obviously finding a dimensionally correct component was crucial. At this prototyping stage, keeping costs low was a priority. We were able to create a single mixed photo-tooling and by doing so, produce all our customer’s designs at the same time. Our solution to prototyping manufacture reduces costs significantly and moved our customer’s project along swiftly, as all design modifications were supplied simultaneously.
 

Our customer required chemically etched formed springs, produced from .004” thick sheet metal. The thickness of the metal and the design of the spring, meant that when the parts were processed through our etching plant, they became tangled and distorted and as a result, the secondary operation of forming the parts, could not be carried out. We therefore, designed the parts to be etched in sheet form, using ‘twist’ style retaining tabs. The parts, reached our in-house forming department, where a simple twist of the part released it from the sheet and it could be successfully formed. This solution reduced rejects dramatically, improved costs and lead time for our customer.
 

Short lead time was of paramount importance to one of PMP’s key customers when launching their new product. We were challenged to lower overall project costs, through clever tooling and component design. Our project management team achieved the tight deadlines, reducing overall cost by designing fit for purpose. The team utilized their 130 man years of design experience, working with the customers’ team from conception to production.
 

From drawings to racing in Japan within 7 days.

A manufacturer of production racing cars required the wheel hub shown to be installed into a single seater racer in Japan within 7 days following an unexpected design change. Our CNC machine shop worked 24 hours a day to make this high specification component including heat treatment; an example of the quality of manufacture and service.
 

Prototypes to production on short lead times.

The components shown require machining and assembling. The batch sizes can vary from ten off to thousands off. Our machine shop has a wide range of machinery and our workforce an equally wide range of skills. The culture of outstanding customer service enables us to deliver reliably on unusually short lead times.
 

Low tooling cost for batches of 200.

This complex component enables a paper print out from an electronic measuring instrument to be torn off from the roll. The requirement is for batches of just 200 and so conventional injection mould tooling would have made the unit cost exorbitant. By careful Manumold tool design, including detachable inserts to create the paper path, the tooling costs became only 20% of the conventional alternative.
 

Hard soft technology with metal insert gives strength and shock resistance.

A manufacturer of safety stair gates required a component which could be adjustable, give a soft cushion against the wall, and yet be strong enough to resist a child pushing against it. This was achieved using a combination of inserts, automatic mouldings and a thermoplastic over moulding. The end result is a sophisticated, low cost component. 
 

A 48% saving was made by converting this part from a metal fabrication to plastic.

The component shown is used as an indicator on petrol tankers. It used to be a welded metal fabrication and then painted. We now mould this in grey plastic around metal inserts and glue in place an acrylic window, which we also mould. Structural integrity and careful selection of materials were important aspects of the new design.
 

Hard soft technology to promote the company brand and reduce child injuries.

We were asked to develop the technique to enable the production of infant feeding utensils in a combination of hard and soft plastic. The result is automatically moulded hard components overmoulded with soft plastic using the Manumold process. The final product is both highly functional and promotes the company brand in two colours.
 

Dog biscuit cutter designed and built in 10 days from 'thumbnail' sketch.

A manufacturer of dog biscuits needed to manufacture a new shape of biscuit for a major retailer. Our engineers visited the manufacturer's site and then came up with a design of cutter to fit the production machinery. The manufacture of the cutter required detailed CAD production drawings, laser cutting, forming, welding, machining and plating. The entire project was managed by our engineers in just 10 days.
 

This product is now manufactured and assembled by us in house saving 28% of the previous cost.

The device measures the length of continuous paper, passing through large printing presses. The manufacturer used to buy in components and assemble the units themselves. We have saved the customer significant costs by carrying out this process and supply the units complete with serial numbers and test certificates.
 

Decorative Frieze for Lazards Bank

Photofabrication has manufactured decorative panels for the prestigious new headquarters of Lazards Bank in London. The external frieze consists of 40 etched stainless steel panels depicting 20 images of the British Isles. The images were made from original drawings, watercolours and etchings by Norman Ackroyd, Royal Academican. The drawing shows one of the sketches by Norman Ackroyd used for the project.