Mini Door, Maximum Challenges: How Our Team Overcame a Tricky Build

At Prototype Projects, we’re best known for our 3D printing, CNC machining, vacuum casting, and model making services, but sometimes, a project comes along that pushes us well outside of those boundaries. One such job was a recent request to make a miniature door. It wasn’t just small in size, it came with a full set of big challenges.

Jordan, one of our experienced RP Technicians, took the lead on this project. Despite his years of experience, this tricky build tested his skills in unexpected ways. The entire job relied on traditional woodwork, an unusual but not unfamiliar route for our model makers.

From the outset, the drawings and CAD data didn’t align. After checking everything thoroughly, Jordan decided to rely on the CAD dimensions to guide the build.

Next came the material challenge. The specified MDF wasn’t available in the size we needed, so Jordan improvised by using builders’ batten instead. It wasn’t an exact swap, but with some clever adjustments, it worked.

Aesthetic finish was also a hurdle. The plan was to apply a vinyl wrap to the door, but it simply wouldn’t stick to the wood, leaving behind an uneven, messy finish. Rather than push ahead with a subpar result, Jordan took matters into his own hands, sanding and painting the door to achieve a far better look.

Then came the hardware. All the hinges, handles and fittings had been supplied based on a full-size door, while our mini version was half the thickness. Unsurprisingly, none of the parts fit. But instead of throwing in the towel, Jordan shaped and ground down each component to make them work.

Reflecting on the build, Jordan commented:

A lot of the fitment issues could’ve been avoided if the design thickness matched a standard door. If we’d had the opportunity, we might’ve suggested tweaks to the design and flagged that vinyl doesn’t play well with rough wood, however time was against our client. But despite all the challenges, the end result looked decent!

This project is a great example of how our work isn’t just about 3D printing. It’s about solving problems, adapting to what’s in front of us, and finding practical ways to deliver results, even when the spec throws a curveball.

Whether it’s a 3D printed prototype, a fully finished CNC part, or a one-off model made from timber and determination, we take every project seriously, and we do what it takes to make it work.

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Contact us on 01763 249760 to discuss your own tricky build.

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