Prototyping can be an extremely valuable step in product development. This provides us with a real-life product to analyze, test, and improve upon if needed, before we begin final production. Our goal is always to build prototype parts that would match the quality of a final production unit. The idea being, that you can show your product to your marketing team, your customer, and of course to test and verify that it meets your specific product requirements.
Quite a bit of engineering goes into building the prototype units. This is where your product will benefit from over 20 years of overmolding experience. We are typically most successful when we work hand in hand with our customer to create a product that meets the requirements. We will analyze and recommend overmold thicknesses, strength requirements, surface requirements, implementation of light pipes, bushing inserts, etc. followed by mold-flow analysis. We call this DFM+. After the best approach is determined, we will build a relatively simple single cavity tool. The goal in prototyping is to produce final production-like components.
The lessons learned in our prototype phase are then implemented when scaling up for volume production, multi cavity tools, with ejector systems, shuttle table operation etc. as needed.