Low-volume batches, mostly scientific and medical instrument housings in the low hundreds, made in-house by vacuum casting, CNC machining and 3D printing, then finished, assembled and inspected before dispatch.
Our workshop is set up for both rapid prototyping and scaled production, with each machine in place to solve a specific part of the job.
Many of our clients are product design consultancies working on medical devices and consumer products. They own the design and the client relationship; we are the manufacturing partner behind them, taking their CAD through design for manufacture to prototypes, trial batches and low-volume production, with NDAs as standard.
Multi-axis milling and turning for accurate parts that need to behave like the final thing.
Additive manufacturing for fast iteration, functional testing and early proof of fit, form and function.
This is where detail gets locked in. Finishing, assembly and inspection happen in-house, so parts leave us looking right, working right and ready for what comes next.
Polishing, paint, VDI textures and soft-touch coatings, applied in-house.
We build complete units in-house, catching fit and function issues early and keeping progress moving.
Parts are inspected against specification before dispatch, with dimensional and visual checks as standard and more on request. We record the materials, pattern and mould numbers, who made the parts and the check results, and only around 1 to 2% of castings are rejected and remade.
We manufacture low-volume batches, mostly scientific or medical instrument housings and components in volumes of the low hundreds, typically by vacuum casting so self-coloured cast assemblies can go straight to market.
This suits early product release, field trials, or products whose sales will always be low. We can include full assembly, printing and the other services needed to get the product box-ready.
For printed runs without tooling, see SLA batch production.
Bridge tooling and bridge production
While your production tooling is being made, we can supply bridge production runs of 1 to 500+ units, so you can get to market or start clinical trials sooner. Parts are vacuum cast or CNC machined to the specification of your approved prototype. See vacuum casting and CNC machining.
Production runs we have made
Prism 200 casework for Cambridge Consultants: IP-rated, drop-tested vacuum cast case sets for hostile conditions, around 10 multi-part sets a year for ten years, now numbering into the low hundreds.
Meridian 8K loudspeaker cabinets: after proving the process on the first prototype pair, we made hundreds of cabinets over many years.
Chrome whisky bottle cases: we designed the cover, proved it with 3D printed and machined prototypes, then managed 1,000 plated injection mouldings with our partners and fitted them to the bottles in our workshop.
Production parts we have made
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Bridge production means making early batches while production tooling is being made, so launches and trials do not wait. We use vacuum casting, SLA, Carbon DLS or CNC machining, depending on the part and the quantity.
Vacuum casting runs are 10 to 500 parts, SLA batches are typically 20 to 200 with thousands possible, and trial batches are usually 20 to 500 identical parts. We have run Carbon DLS batches of 1,000 small parts.
Yes. We assemble parts in house, including fitting electronics, and check them before they leave. For assemblies, we agree with you what needs testing, then either invite you in to help or check the first assembly with you before building the rest. Inspection is agreed for each job, usually sample checks.
Yes. Complete Fabrication is ISO 9001 certified (certificate 7774, ISOQAR, UKAS).
Making parts in tens or hundreds rather than tens of thousands, usually without the cost and lead time of steel injection mould tooling. We do it by SLA, Carbon DLS, vacuum casting and CNC machining, with finishing, assembly and inspection in-house.
