Prototyping and Manufacturing Services

Rapid prototyping services, all under one roof

These are the ways we help you move from concept to something real
Choose what helps you learn faster, prove what matters and keep momentum. For fast prototypes from CAD, see our rapid prototyping services.

3D Systems Viper SLA machine running Accura Xtreme Grey resin
3D printing

3D printing

Accurate parts for early tests and design reviews in SLA, Carbon DLS, FDM and DLP, with a 24-hour standard turnaround on SLA. For tough thermoplastic parts, see FDM 3D printing. For transparent parts, see clear 3D printing.

Machining

CNC machining

Precision-machined parts for tight tolerances, repeatable quality and production-ready decisions

CNC machined clear acrylic block with threaded internal channels
Rapid prototyping workshop benches with staff at work

Working prototypes

Looks-like, works-like models with inserts, assemblies and electronics fitted, ready for user trials, investor demos and design sign-off. See our model making services.

Finishing

Painting and finishing for prototype and production parts

Colour matched to Pantone, RAL or your sample, with metallic and soft-touch coatings and VDI textures, from two in-house spray booths and our own paint mixing system.

Node speaker gloss red paint finish
Blackfin mobile prototype painted with flexible rubber gasket
Seals

Flexible Gaskets

Silicone and polyurethane seals and gaskets cast to your specification, with moulds made in-house, for prototypes and production runs.

Casting

Vacuum casting

Self-coloured polyurethane parts close to injection-moulded quality, in batches of 10 to 500, from a team that has been vacuum casting since the 1980s.

Silicone mould for vacuum casting polyurethane parts
Meridian speaker 7K production and paint finish
Advice

Beyond the standard routes

Not every project fits one process. We often combine them: an SLA master pattern for vacuum casting, CNC inserts in a cast housing, then paint and assembly.

Design

Design development

We refine ideas into buildable designs, with manufacturing, assembly and real-world use in mind. We also work as the making partner for design consultancies.

DRW SAMBA II diagnostic instrument with its white turret component
Vacuum-cast production part for an Owlstone breath analyser
Production

Production runs

Bridge production runs of 1 to 500+ units while your production tooling is being made.

Our approach

Choosing the right process is half the job

Medical devices need biocompatible materials and paperwork; consumer products need a finish that survives a design review. We plan the process, material and schedule before any machine starts, because the wrong process usually costs more time than it saves. To compare tolerances and lead times side by side, see our process comparison table.

Complete Fabrication at a glance

  • Making prototypes in Whittlesford, near Cambridge, since 1986.
  • ISO 9001 certified (certificate 7774).
  • Carbon Certified Production Partner, and the second UK company to partner with Carbon.
  • SLA: CAD by 5:30 pm, usually delivered the next day when capacity allows. Batches typically 20 to 200 parts, up to thousands.
  • CNC machining: 3 days for most work, with a 24-hour rush available.
  • Vacuum casting: batches of 10 to 500 parts.
  • Carbon DLS: batches of up to 1,000 small parts, with no tooling.
  • Painting, finishing and assembly in-house, and NDAs as standard.

Explore 3D printing in Cambridge, vacuum casting, medical device prototyping, our materials and the pricing guide.

pharmaCo inhaler prototype in SLA with packaging

Fast turnaround

SLA in 24 hours as standard, CNC in 3 days, vacuum casting lead time confirmed at quote.

Keurig coffee machine prototype with CNC machined parts

Tolerances that hold

SLA to ±0.15 mm, CNC to ±0.10 mm, vacuum casting to about ±0.2 mm on small parts and up to ±0.7 mm on large castings.

Owlstone breath tester product

Paperwork included

Certificates of Conformity for materials and manufacture, NDAs as standard, and ISO 9001 certified.

Results

Numbers that speak clearly

The work speaks for itself. These numbers show the scale, speed and consistency behind it.

zone dome for running unlimited working prototype

Projects completed

Thousands

From concept to production across multiple sectors

Industries served

20+

Medical, defence, robotics, aerospace, automotive, marine and consumer products, among others

Years with our top clients

20

Most of our biggest clients have worked with us for close to two decades

Rapid prototyping and manufacturing services: questions

Can one company take my design from idea to finished parts?

Yes. In our Whittlesford workshop we develop designs and check them for manufacture, make prototypes by SLA, Carbon DLS, FDM, CNC machining and vacuum casting, then run small batches, paint, finish, assemble and pack. You deal with one team from the first model to the finished parts.

Do you work with companies outside Cambridge?

Yes. We make prototypes and small batches for product teams across the UK, with overnight delivery to all areas of the UK. Clients near Cambridge can collect from the workshop or use our local delivery.

Which service should I start with?

Send us your CAD or drawings, the quantity and what the part has to do, and we will recommend the route. As a guide: SLA for detailed prototypes, CNC machining for metal and production-grade plastics, Carbon DLS for tough functional parts, and vacuum casting for 10 to 500 parts in production-like plastics.

What services does Complete Fabrication offer?

3D printing (SLA, Carbon DLS, DLP and FDM), CNC machining, vacuum casting, painting and finishing, model making, trial batches, low-volume production, flexible gaskets and design for manufacture reviews. Everything is made, finished and assembled in our workshop near Cambridge.

Do you make plastic prototypes?

Yes. We make plastic prototypes by SLA, Carbon DLS and FDM 3D printing, by vacuum casting polyurethanes that behave like production plastics, and by CNC machining engineering plastics such as ABS, nylon, acetal, polycarbonate, acrylic and PEEK. We recommend the process for your quantity, finish and test.

Do you offer model making?

Yes. We make block and appearance models for design reviews, photography and investor meetings, looks-like, works-like prototypes, and full-size display models, all made, painted and assembled in our own workshop. See model making.

Do you offer low-volume production?

Yes. We make low-volume batches, mostly scientific and medical instrument housings in the low hundreds, by vacuum casting, CNC machining and 3D printing, then finish, assemble and inspect them before dispatch. Bridge batches can cover the wait for production tooling.

Can you make batches for user trials or hall tests?

Yes. We make batches of 20 to 500 identical prototypes, finished to an approved first-off sample and checked unit by unit, plus the packaging to go with them. See trial batches.

Do you make packaging prototypes?

Yes. We design, print and assemble bespoke packaging, so you can test the pack and the unboxing alongside the product.

Do you make gaskets and seals?

Yes. We cast RTV silicones across most Shore hardnesses and polyurethane elastomers in tools made in-house: CNC-machined tools for longer runs, or 3D printed tools for quick, low-cost short runs. See flexible gaskets.

Can you review my design before I order parts?

Yes. We check every file before we make it and tell you if a change would make the part stronger, cleaner or cheaper to make. For a fuller design for manufacture review, send your CAD, the quantity you expect and the finish you want.

Can you assemble prototypes with electronics fitted?

Yes. We build looks-like, works-like prototypes with mechanisms, inserts and electronics fitted, ready for user trials and design sign-off.

Do you make jigs and fixtures?

Yes. We make jigs and fixtures, often by FDM in real thermoplastics. For the maker of the BMW Mini dashboard assembly, we designed jigs that took production to a 100% pass rate. See the production jigs case study.

Can you make clear parts or very large parts?

Yes. We print clear SLA parts and polish them, and machine and polish clear acrylic. For large parts, FDM builds up to 800 × 800 × 1,000 mm in one piece, and larger designs can be split and joined. See clear 3D printing and large format 3D printing.

Do you offer plating?

Yes. We plate copper, nickel and gold in-house onto smaller parts, up to about a 150 mm cube, for a metallic finish on SLA prints.

Got a CAD file or a drawing?

Tell us what you are working on. We will help you choose the right route and get the first parts moving.