• 27 Kaka Street, Favona, Auckland 2024, New Zealand
  • Rapid Prototyping



    We have the capability to manufacture casting prototypes using both 3D printing and machining from high density foam and then cast those designs in a range of metal alloys. Although the finish may not be to the same high quality as a part from wax, a fully functional casting will result.

    As significant skill and expertise is applied in the development phase with one-off castings such as prototypes, costs are higher than production run quantities.    

    Rapid prototyping is ideal for:

    • Proof of concept for design verification. Nothing beats a sample in hand when developing a product.
    • Confirming part dimensions before committing to tooling. If certain cast dimensions are important then running a prototype can firm up shrinkage allowances.
    • A high value component where very few are required and the additional costs of using this process is still cost effective. 


    In view of the popularity of 3D printing this process tends to dominate with FDM (Fused Deposition Modelling) also known as FFF (Fused Filament Fabrication) using PLA the most common method and the process we use. In some circumstances machining foam can be preferable. We have considerable experience using both methodologies.

    We have a number of 3D printers with extensive 3D printing capability and can print designs up to 500mm x 500mm x 500mm. We can also join multiple 3D printed and foam machined parts to build complex designs. The larger sizes may subject to handling constraints limiting just how large a part can be cast. 

    Surface finish will generally not be as good as a part from wax as printing artifacts will remain, even after a tidy up. Lamination lines and signs of the support structures generally remain visible, but surprisingly good results can be achieved with some effort.