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From concept to small-batch production
Consumer product development moves quickly, and the pressure to show something tangible – to investors, retailers, or the wider team – rarely lets up. Whether you need a concept model for a pitch, a functional prototype for user testing, or a pre-production batch before committing to volume tooling, the quality of what you put in front of people matters.
Prototype Projects has supported industrial designers, product development teams and hardware startups for decades, producing parts and models at every stage of the development cycle. Our facility in Royston, Hertfordshire is ISO 9001 and ISO 14001 accredited; all work is carried out in-house, and our finishing team produces parts to presentation standard as standard – not as an afterthought.
From your first concept model to a pilot production run, we work with you at every stage.
Why consumer product teams work with us
Finishing to presentation standard. Surface finish and appearance matter in consumer products in a way they don’t in every other sector. Our in-house finishing team paints, lacquers, textures and colours parts to a level most prototyping suppliers can’t match – including rubberised soft-touch coatings, SLS dyeing, vacuum metallising, and Pantone or RAL colour matching.
A full range of processes under one roof. From large-format SLA for housing and enclosure models to vacuum casting for production-representative batches and injection moulding for pilot production, we cover the full development journey without the need to manage multiple suppliers. That means fewer handovers, less risk of programme knowledge being lost, and a simpler conversation when requirements change.
Fast turnaround when you need it. SLS, SLA and DLP parts are available with overnight dispatch. CNC machined parts are available from three working days. When a pitch or a product review has a fixed date, we’ll work to meet it.
DFM guidance included. Our team reviews files for manufacturability before quoting as a matter of course. If a design has features that will cause problems in production – wall thickness issues, draft angles that need adjusting, geometry that won’t demould – we’ll flag it before the job goes into production, not after.
ISO 9001 accredited quality management. Our independently accredited quality management system means that parts are consistent, traceable and delivered to a known standard – important when you’re handing prototypes to investors, retailers or test participants, and essential when you move to pilot production.
UK-based, in-house, and secure. All work is carried out at our Royston facility. No outsourcing, unless from necessity to one of our approved suppliers, and agreed with you. Your designs stay on our own server, and our team treats every project with the same discretion, whether it’s a concept sketch or a market-ready product. NDAs signed on request. Our Cyber Essentials certification means your design files and project data are protected by independently verified cybersecurity controls – an important consideration for any team sharing confidential CAD files and unreleased designs with a supplier.
Services relevant to consumer products
SLA 3D Printing: Our SLA 750 machine produces large, highly accurate resin parts with a smooth surface finish – ideal for housing and enclosure models, ergonomic evaluation parts and concept models that need to look the part. A wide range of finishing options is available, including paint, lacquer, rubberised coating and vacuum metallising.
Learn more about SLA →
PSLA 3D Printing: Projection stereolithography produces parts with a very fine surface finish, particularly suited to consumer products where surface quality on smaller parts is critical. The availability of production-grade materials and capability for textured surfaces, if required, make it a viable production solution for the right applications.
Learn more about PSLA →
SLS 3D Printing: Strong, functional nylon parts without tooling – well-suited to enclosures, internal mechanisms and structural assemblies within consumer products. SLS parts can be dyed, giving finished parts a consistent appearance that works for product review and user testing alike. Overnight dispatch available.
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DLP 3D Printing: A range of materials including flexible, flame-retardant and standard grades. Particularly relevant for consumer products requiring flexible components, soft-touch features or parts with specific material performance requirements.
Learn more about DLP →
Vacuum Casting: Small batches of polyurethane parts – from five to fifty – in a range of materials from soft elastomers to rigid plastics, all closely representing injection moulded production parts. Ideal for user testing, retail buyer samples, investor demonstrations and pre-production evaluation. Overmoulding is available, and parts can be produced in colour.
Learn more about Vacuum Casting →
CNC Machining: Five-axis milling and CNC turning for functional components, mechanical assemblies and structural parts. Particularly relevant for metal components within consumer products – buttons, chassis parts, hinges and similar details – and for functional test parts where material properties matter.
Learn more about CNC Machining →
Injection Moulding: UK-made tooling and low-volume injection moulding for programmes moving from prototype to pre-production. Aluminium and steel tool options available depending on volume requirements and budget. Our team can advise on tool type and material selection at the quoting stage.
Learn more about Injection Moulding →
Model Making: Hand-finished presentation models, scaled display models and exhibition pieces – produced to a level of finish that represents the product at its best.
Learn more about Model Making →
Typical applications
We regularly produce parts and models for applications including:
- Consumer electronics housings, enclosures and interface components
- Wearable product casings and ergonomic evaluation models
- Small domestic appliances and accessories
- Sports, leisure and outdoor product prototypes
- Concept models and presentation pieces for investor and retailer pitches
- User testing and focus group samples in production-representative materials
- Pre-production batches for market evaluation and retail buyer samples
- Overmoulded ergonomic grips and soft-touch consumer product components
Finishing options for consumer product prototypes
Surface finish is often what separates a prototype that generates confidence from one that raises questions. Our in-house finishing team offers:
Paint and lacquer: primer, colour coat and lacquer to satin, gloss or matt finish, including Pantone and RAL colour matching. Textured finishes (fine, medium, coarse) are available on SLA and DLP parts.
Rubberised soft-touch coating: applied over a painted surface, giving a tactile soft-feel finish suitable for grips, handles and consumer electronics casings.
SLS dyeing: consistent colour throughout the part available in black as standard; a wider range of colours is available via one of our trusted suppliers. Parts can be dyed and lacquered for a more refined surface.
Vacuum metallising: a mirror-finish metallic coating applied to SLA parts, suitable for decorative consumer product components and presentation models (this process is outsourced to one of our trusted suppliers).
Ready to discuss your project?
Whether you’re at the concept stage or preparing for pre-production, we’re happy to talk through your requirements before you submit a quote request. We’re particularly used to working with product teams on tight timelines and to working through finishing requirements in detail before a job goes into production.
Contact our team on 01763 249760 to discuss your next project, or request a quote using the form below.
Request a Quote
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.
To request a quote for any of our other technologies/services, such as Vacuum Casting, Model Making and Laser Cutting, please complete this contact form.
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