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Welcome to Prototype Projects
Elvie case study
Improving women’s lives with smart tech
Elvie was founded in 2013 by Tania Boler with the mission to improve women’s lives through smarter technology. Tania wanted to develop meaningful products to help support women, particularly new mothers.
As a result, the company approaches problems as women and solves them as engineers, scientists and designers, creating new products and solutions.
Elvie Pump – the vision
Having achieved success with Elvie Trainer, an award-winning Kegel training device for a strong pelvic floor, Elvie focused its attention on the development of a new product: Elvie Pump.
The Elvie team interviewed many women to find out what was missing from existing breast pumps. The results enabled Elvie to re-imagine what a breast pump that would fit into the busy life of a breast-feeding mum should do.
The findings showed that mums wanted a device which was silent and discrete, truly hands-free and that could be used at home, at work or on-the-go.
The team imagined an all-in-one, rechargeable device without wires or hoses, where the milk-collecting elements of the pump were removable so they may be sterilised. The pump would need to be compact and shaped in such a way so that it would discretely fit inside a maternity bra. This design feature would mean the pump would work hands-free.
With a clear, research-based vision for the product, Elvie set about creating a dumb block model from sketches to validate this vision.
Prototyping the Elvie Pump
Moving through the product development stages, Elvie worked with Prototype Projects on three iterations. The first prototype was a limited function prototype, which would enable basic testing of the new technologies and of the seal to ensure pressure would be maintained during pumping.
As the product would be coming into contact with the body and breast milk, it was important to ensure the device complied with USP Class IV certifications.
Using Prototype Projects’ dedicated SLA machine, which is used to create medical and drug delivery devices only, the second prototype was built using a mixture of SLS PA Nylon, SLA Accura Xtreme and SLA Accura ClearVue technologies and materials.
This prototype was used to develop the size and shape and ensure functionality. It was left with trial users for a two-week test period
The final prototype was used to cross check the design with the original vision and further refine pumping efficiency. This prototype was also used in conversations with mass-manufacturing partners before moving to the engineering build stages.
Speed and quality
Adam Rollo, Head of R&D, began working for Elvie in 2016. Having previously worked with Prototype Projects while employed by Shark Ninja, Adam obtained quotes from Prototype Projects and competitors. He evaluated the quotes for price, speed and quality. Prototype Projects was subsequently appointed.
Adam said,
“At one stage we needed 15 prototypes at once for an extensive user trial. Prototype Projects’ next day dispatch was incredibly valuable during this stage as the fast turnaround times provided us with great flexibility so we could manage deadlines.”
The finished Elvie Pump is now available to buy as a single or double pump kit. It is hands-free, silent and worn discretely inside a standard nursing bra.
The device can be controlled by an app, developed by Elvie, which records how much milk has been pumped and the frequency of pumping. The device is responsive and so, working with the app, it can switch off automatically.
Adam continued,
“The quality of the parts we received from Prototype Projects was to spec, meaning we had no nasty surprises. The Haribo’s in the delivery boxes are always a great reward at the end of each prototyping stage!
“We are working with Prototype Projects again on our next project which is a testament as to the high quality of parts and great customer service we receive.”
About us
Prototype Projects, established in 1980, is a specialist in the manufacture of prototypes. We are experienced in 3D Printing, CNC Machining, Rapid Prototyping, Model Making and Additive Manufacturing. We’re located in Royston, Hertfordshire.
As a leading prototyping company we provide a completely integrated design-to-production service including, model making, rapid prototyping, 3D printing, finishing and additive manufacturing of production parts.
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To find out more about us and the services we offer, please read on.
Your parts. Your process.
We offer a wide range of 3D printing solutions as well as CNC machining & milling, vacuum casting and laser cutting.
- 3D Printing
- SLA – Stereolithography
- SLS – Selective Laser Sintering
- PµSL – Projection Micro Stereolithography
- DLP – Digital Light Projection
- CNC – Computer Numerical Control Milling (4 Axis) & Turning
- Vacuum Casting
- Laser Cutting
- Model Making
Your parts. Your speed.
3D Printing
We offer these dispatch options for 3D printing so you can have your parts at your speed:
- Express: next day dispatch if ordered before 4.30pm*
- Standard: in 3 working days
- Economy: in 5 working days
Click here to find out more about our service levels and dispatch methods.
CNC Machining
We offer these dispatch options for CNC machining so you can have your parts at your speed:
- Express: in 3 working days
- Standard: in 7 working days
- Economy: in 12 working days
Your parts. Your finish.
3D Printing
Depending on the purpose of the part, we offer a range of different finishing levels available on all 3D printing. Below is an overview:
Using our specialist graining process, SLS and SLA parts can be textured, giving them an ‘Off Tool’ look, such as leather or other natural materials. It is also possible to apply surface texturing to DLP parts.
We offer a consistent and repeatable SLS dyeing service, using our ‘Print-to-Product’ workflow. SLS parts can be precision dyed in virtually any colour. In addition to SLS dyeing, all models can be spray painted in our Paint Shop.
Click here to find out more about our 3D Printing finishing options.
CNC Machining
We offer an extensive range of finishing options for CNC machined prototype parts. Below is an overview:
Finishes can be applied for aesthetics or functionality – including EMI/RFI shielding on plastic parts – with the choice being heavily dependent on the base material.
We have in-house facilities for both wet painting and manual polishing. Other processes, such as anodising and powder coating, can be subcontracted to local specialists.
Click here to find out more about our CNC Machining finishing options.