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Aerospace and Defence Sector

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UK manufacturing for high-performance parts

When parts need to perform under pressure – and confidentiality isn’t optional – you need a supplier you can rely on completely.

Prototype Projects has supported aerospace and defence teams across the UK for decades, producing prototypes, test fixtures, and low-volume production parts that meet the demands of some of the most technically challenging work in engineering. Our facility in Royston, Hertfordshire, is ISO 9001 and ISO 14001 accredited, and all work is carried out in-house, in the UK.

Whether you’re developing a UAV component, an avionics housing, a structural test part or a system mock-up for field evaluation, we’ll help you select the right process and materials – and deliver to the timescale your programme requires.

Why engineers in aerospace and defence work with us

UK-based, in-house production All machining, printing and finishing takes place at our Royston facility. No outsourcing, no third-party handling of your files or parts.

Confidentiality as standard We understand that project details, part geometries, and programme timelines are sensitive. Your data stays secure through NDAs, and our team operates with discretion as a matter of course.

ISO 9001 accredited quality management Our quality management system is independently accredited, giving you the traceability and process control that defence and aerospace supply chains demand.

A range of processes under one roof From CNC machining in metals and high-performance plastics to large-format SLA, SLS, and vacuum casting, we can support multiple requirements within a single programme, without the overhead of managing several suppliers.

Inspection services We offer dimensional inspection and can provide inspection reports alongside your parts – particularly valuable when you need to verify tolerances on functional prototypes before committing to production tooling.

Flexible lead times Overnight dispatch is available for certain 3D printing processes. CNC machined parts are available from three working days. When your programme has a hard deadline, we’ll work to meet it.

Services relevant to aerospace and defence

CNC Machining: Five-axis milling and CNC turning in aluminium, stainless steel, PEEK, acetal and other engineering materials. Suitable for structural brackets, mechanical interfaces, test fixtures, housings and jigs. Tolerances to ±0.05 mm available.
Learn more about CNC Machining →

Large-Format SLA 3D Printing: Our SLA 750 machine produces large, highly accurate resin parts – ideal for full-scale mock-ups, enclosures, and system evaluation models where surface quality and dimensional accuracy matter.
Learn more about SLA →

Selective Laser Sintering (SLS): Strong, functional nylon parts without tooling. Well-suited to complex geometries, ducting, brackets and internal structures where lightweight performance is important.
Learn more about SLS →

Vacuum Casting: Polyurethane parts in small batches – useful for evaluation models and test components where material properties need to approximate a final moulded part.
Learn more about Vacuum Casting →

Injection Moulding: For programmes moving from prototype to production, our UK-made tooling and low-volume injection moulding service delivers consistent, production-grade plastic parts.
Learn more about Injection Moulding →

Inspection Services: Dimensional inspection and inspection reports available alongside your parts, supporting quality assurance at the prototype and pre-production stage.
Learn more about Inspection →

Aerospace and Defence

Typical applications

We regularly produce parts for applications including:

  • Structural prototypes and load-bearing test components
  • Avionics housings and mechanical interface parts
  • UAV and drone airframe components and brackets
  • Test fixtures and ground support equipment
  • Enclosures and system mock-ups for field evaluation
  • Low-volume production parts for defence equipment programmes

Materials commonly used in aerospace and defence work

The right material choice is critical in this sector. Our team can advise on the best option for your application, but commonly specified materials include:

For CNC machining: Aluminium 7075 (high strength-to-weight), Aluminium 6082 (good machinability, general structural use), Stainless Steel 316 (corrosion resistance), PEEK (high-temperature performance, chemical resistance)

For 3D printing: SLA HT300 (high-temperature resin, suitable for testing under thermal load), SLS PA12 (strong, functional nylon), DLP FR materials (flame-retardant grades for electronic enclosures and housings)

View full materials datasheets →

Ready to discuss your project?

Our team is used to working with engineers and procurement teams on programmes where accuracy, confidentiality and reliability matter. We’re happy to talk through your requirements before you submit a formal quote request.

Call us on 01763 249760, email us, or use the quote form below.

Contact us

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Injection Moulding

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    Step 1

    Your Details

    Project Information

    Project name or unique reference

    Quantity required - initial run, and ongoing volumes, if relevant

    Intended use

    Deadline or target date

    Part Information

    File upload

    Please add up to three files (e.g. your CAD file, 2D drawing, and any additional information) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

    Part dimensions (if not obvious from file)

    Tolerance requirements (standard or tighter)

    Cavity Finish

    Do you require multi-impression or multi cavity options? (we can advise if unsure)

    Material Requirements

    Preferred Material or Polymer (if known)

    Material properties required (strength, flexibility, transparency, temperature resistance etc)

    Colour requirements (standard, custom, Pantone or RAL match)

    Food or medical grade requirement

    Tooling

    Tool type preference

    Expected tool life

    Do you require tool ownership

    Support and DFM

    Do you need Design for Manufacture (DFM) review?

    Any known undercuts, inserts, overmoulding, or special features?

    Additional Information

    Budget range (optional, but can help speed quoting)

    Any other notes or requirements?

    Which dispatch method do you require?

    How did you hear about us?

    CNC Low Volume Production

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      About you

      PART 1

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 1 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 2

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 2 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 3

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 3 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 4

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 4 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 5

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 5 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 6

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 6 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 7

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 7 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 8

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 8 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 9

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 9 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Add another CNC part to this quote?

      PART 10

      Material

      Which billet size best fits your part?

      Tolerance

      Threaded holes?

      Do you require an inspection report?

      How many offs do you require for this part?

      Upload part 10 file

      Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

      Additional information

      Marketing

      How did you hear about us?

      CNC Machining

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        About you

        Which dispatch method do you require?

        PART 1

        Material

        Threaded holes?

        Upload part 1 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 2

        Material

        Threaded holes?

        Upload part 2 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 3

        Material

        Threaded holes?

        Upload part 3 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 4

        Material

        Threaded holes?

        Upload part 4 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 5

        Material

        Threaded holes?

        Upload part 5 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 6

        Material

        Threaded holes?

        Upload part 6 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 7

        Material

        Threaded holes?

        Upload part 7 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 8

        Material

        Threaded holes?

        Upload part 8 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 9

        Material

        Threaded holes?

        Upload part 9 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Add another CNC part to this quote?

        PART 10

        Material

        Threaded holes?

        Upload part 10 file

        Please add up to three files (e.g. your 3D model and up to two supporting documents) for this part. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP and IGES files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

        Additional information

        Discount code

        Marketing

        How did you hear about us?

        Please Note: requests for our 3-Day production speed must meet our 3-Day criteria. All final data for our 3-Day production speed is required by 4.30pm.

        3D Printing

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          About you

          Which process do you require?

          Material

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          Material

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          Which material do you require?

          Please specify which DLP material you require (please note: we can only offer 7-12 day dispatch for materials we do not stock):

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          Material

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          Which production speed do you require?

          Material

          Which finish level do you require?

          Which production speed do you require? (i.e. how quickly do you want it made) You can select more than one option if you'd like to see the different pricing options.

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          Please add up to 10 files. Please note, for security reasons, we do not accept zip or RAR attachments. We prefer STEP files, but will accept STL files. If you need to send us large files, please email them to us at office@prototypeprojects.com or call us on 01763 249760

          Marketing

          How did you hear about us?

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