Innovators often sources alternative prototype parts where required. We will advise when these systems suit your prototype parts.

Email us for a quote - daniel@innovators.net.nz

Innovators in house Objet rapid prototype system

Design Guidelines and file type information for prototypes

FDM is another method used to manufacture rapid prototypes and plastic models. It is one of the most commonly available prototyping and modelling methods available for engineers and designers, and is used across a wide range of fields. The FDM process builds the prototype by jetting liquefied polymers in stereolithographic slices onto a Z-axis platform. By repeatedly dropping the Z axis and adding more STL slices, a full 3D representation is built up. The FDM machine accepts computer generated files and medical CT scans to produce finished prototypes quickly. While FDM models can be lower in resolution compared to other processes we offer, they can be made in a variety of - real production - materials such as ABS, ABSi (translucent ABS), Polycarbonate (PC) and Polyphenylsulphone (PPSF). All these have up to 85% of the strength of parts moulded in the same material, with all the temperature characteristics. We recommend FDM parts for high temperature applications and for large, one-off models, where detail levels are low or features are coarse.

SLS uses a high powered laser to fuse particles of build material together to form a solid prototype. Typically a tray of powdered material is wiped flat and then a laser scans in the X and Y planes to fuse the material into a solid. SLS can achieve high resolution in a wide variety of materials such as Nylon (PA) and Polystyrene (PS).

Direct metal laser sintering is capable of producing metal parts in a process similar to SLS. Materials available include stainless steel and titanium. DMLS is a new technology and thus expensive, however we are able to source parts made with this technology. Please contact us for further information.

We recommend the use of CNC machined parts for high cosmetic applications, especially when multiple units are required. Innovators also recommends CNC machining for very large parts, or in cases where real material properties are critical. If more than two or three sets of parts are required, they can often be produced using CNC at a lower cost than with using 3D printing. However, each case must be taken on its own merits, so please allow us to quote and advise. Machining centres can be used to machine the widest range of materials, such as plastics, ceramics, woods, waxes and most ferrous and non-ferrous metals. Additionally, Innovators capabilities range to high cosmetic painting of machined parts, screen printing of text/symbols and even UV resistant coatings for field trial prototypes that are expected to undergo long-duration trials. We have a range of supply partners who are able to offer these services for cosmetic and industrial/test parts.

Vacuum casting uses a vacuum chamber to suck molten plastic into a silicone mold. Vacuum casting is a fast and cost effective process to produce high quality parts in real plastic for prototype and short run volumes. Most injection moulding plastics, such as ABS, PP, PE, PS, PA, PMMA and PC are available and fine detail as well as undercuts can be achieved.

Many of our customers order casting masters or mold parts from us with the intention of making green sand or silicone molds. Once molds have been made many other materials can be cast. For example a master part can be printed in Objet resin and then a silicone mold made around this part. Wax can now be poured into the cavity to produce patterns for lost wax casting to produce real metal parts.

We can also design and print molds directly in Objet resins to make urethane and silicone parts. Many customers choose this method when they wish to produce many parts by doing the casting themselves. We have even perfected a method for casting multiple colours into a single mold to produce overmold effects.