Low Volume Production

banner_Low volume production

Brecher Prototyping offers highly-sophisticated expertise in urethane castings, which provide an important bridge between rapid prototyping and production. Brecher Proto is your single source for custom manufactured rapid prototypes to low-volume production plastic and metal parts.

Urethane castings from Brecher Proto can be used to closely simulate final injection-molded parts and/or finished products quickly and inexpensively without the investment in metal tooling. Create prototypes and low-volume production components that are virtually identical to injection molded parts, but without the cost and lead time. Cast polyurethanes are ideal for test prototypes, marketing samples, early-stage production parts and other applications where fewer than 1500 pieces per month are needed.

When multiple parts are needed, RTV (room temperature vulcanized) tooling and Urethane casting can be used to fill the gap between prototype and production. Urethane prototypes can be of nearly any size and shape and can be color matched by either a pantone number or a color chip. Whether you require inserts, molded in color/texture or painted in custom color/texture, our Urethane casting team will meet your required specifications.

Cast urethane parts and/or finished products can be completed and delivered in days after completing SRM tooling (silicone rubber molds), and short runs of several hundred pieces can be delivered within weeks in most instances. Silicone Rubber Molds take as little as 5-7 days.

The RTV mold (also known as silicone rubber) is created using a master pattern. The master pattern can be created by CNC machining or 3D printing (FDM, SLA, Polyjet). The platinum based silicone rubber is poured around the master pattern to create a cavity and a core. The master is then removed, leaving a void in which a wide variety of materials may be cast.

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Prototype material can be chosen to match nearly any production material, from 5 shore A to 80 shore D. Some of the many materials that can be used are: two part thermoset urethanes, silicone rubber, wax and epoxies. Silicone molds are capable of reproducing incredible detail, including custom textures. Urethane casting provides fast turnaround. Prototype materials and processes can simulate many of the thermoplastics characteristics of hardness, clarity, flexibility and impact resistance, giving you cast urethane prototype the same look and feel as a true production part.

PERFORMANCE

Achieve the same finish, color,tolerances and material properties as injection molded.

SPEED

Lead time is three to seven days instead of the weeks or months required for hard tooling

COMPLEX PARTS

Produce parts with geometries that would be expensive or impossible to produce with hard-tooling.

LOW COST

Cast urethane is more cost-effective for short runs compared to hard tooling

Applications

  • Product Development:
  • Industrial Design Models
  • Engineering Proof of Concept Models
  • Mechanical Breadboards
  • Performance Evaluation and Testing Models
  • Engineering Check Models (Design Verification)
  • Regulatory Approval Prototypes:
  • UL and CE
  • FDA and Clinical Trail
  • Sales and Marketing Samples:
  • Product Photo Models
  • Sales Samples
  • Market Study Models

Other:

  • Wind-tunnel Test Models
  • Architectural Models
  • Point of Purchase Display Models
  • Exhibit Models
  • Rapid Manufacturing / Low Volume Production
  • Medical and Healthcare
  • Electronics; Packaging, Connectors
  • Homeland Security
  • Military Hardware
  • Consumer Products
  • Production Parts
  • Alpha & Beta Builds
  • Pre-production Parts
  • Functional Prototypes
  • Early Revenue Generation
  • A-Rank Vehicle Components
  • Design & Engineering Verification
  • Assembly Line Verification & Tuning

Industries

  • Consumer Electronics
  • Medical Equipment/Devices
  • Automotive
  • Heavy Equipment
  • Sports Equipment
  • Aerospace/Military

Secondary Operations:

  • Precision Machining
  • Threaded Inserts
  • Custom Machined Inserts
  • Surface coatings:
    • Lacquer
    • Two-part Urethane
    • Epoxy
  • Decorations
  • Hand painting

Our product development and product manufacturing services cater for a wide variety of product development and production requirements, meaning no job is too big or too small for us to be involved with.

 

Our Low Volume Production Services:

RTV Tooling
Cast Urethane Molding
Sillicone Casting (Silicone Molding, prototype molding, micro molding, high volume Molding, short volume molding, liquid resin casting, cast in color)
Low Volume Molding & Assembly services
Pilot production (Pre-production parts & short run production series, pre-series)
Painting Simple Cosmetic or High End Show Models

“They have far exceeded my expectations of delivery, price, accuracy, and customer service. I would be happy to recommend them to colleagues and will definitely consider them for prototyping requirements in the near future.”
–Business Development Director, Industrial Product Design Company

Why not get in touch with us? Our team is ready to help and guiding you on your new and exciting product development journey. You already have an idea? Let’s make it happen

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