Moulding and Prototyping Services

PU Moulding – RIM

Prototype Sourcing & Consultancy

Injection Moulding

CAD / CAM

About Us

With 30 years combined experience in casting and moulding, Ben Ingram and Tom Dunkley founded ID Mouldings in 2019.   Together, we strive to challenge the limitations of the moulding technology, collaborating with our customers to develop new products and produce high-quality, low volume moulded parts.

 

Our core speciality and in-house manufacturing process is Polyurethane Moulding using the Reaction Injection Moulding (PU-RIM) process.  ID Mouldings has the technical knowledge and industry experience to support you with full project delivery – from the initial concept to final production. We will undertake the low volume moulding at our own facility in the West Midlands and commit to using our extensive network of British industry specialists for other areas.

 

Due to our extensive experience, the mouldings we produce have widespread applications and functions across a huge variety of sectors.  Current collaborations include: Automotive Interior & Exterior, Automotive Development, Medical, Health & Leisure Equipment, Food & Beverage and Motorsport Mouldings.  We pride ourselves on the diversity of our customers and constantly seek to expand our product range.

PU Moulding – RIM

(Polyurethane Reaction Injection Moulding)

Over the last decade, low capital investment in tooling and rapid tool creation have resulted in a resurgence of PU-RIM Moulding.  Therefore, this is the perfect process for low volume production and prototyping of moulded components.

After placing an order with ID Mouldings, you can expect tooling lead-times to be typically two to three weeks.  Our expected tool life is up to 1,000 shots; this is obviously dependent upon the component’s geometry and complexity.  In addition to single cavity tools, ID Mouldings can also offer you multiple cavity and family moulds.  All tooling has the potential for the over-moulding of metallic or composite support structures; the inclusion of threaded male/female inserts are also common practice with us.

 

To produce your mouldings or components, we have access to a wide variety of quality resin grades which vary according to the application or requirement of your product.  Among many others, these include: high impact, fire retardant, heat resistant and UV stable.

Prototype, Low Volume and Production Consultancy

ID Mouldings has the expertise and knowledge within the manufacturing industry to be able to advise on the best route to production for prototype projects, low volume projects and larger volume production. Whether it be a visual concept model, a working test prototype or production intent components, we will direct our clients in the right direction depending on the intended application and requirements. ID Mouldings strongly supports and are passionate about British manufacturing; we will not compromise on quality for cost when nominating the route to production. Our colleagues include additive manufacturing, CNC machining, injection moulding, prototyping, metal fabrication and finishing/painting experts.

3D Printing

SLA

(Stereolithography)

Stereolithography is an excellent process to produce extremely accurate physical models of 3D CAD data. Using replicate materials of PP, ABS and clear PC, build layers (as small as 0.05mm) can produce fine details on parts on a single build envelope of 350mm x 350mm x 400mm. The post-processing of the SLA models can include painting (gloss, textured and light spark finishes) which can transform the models into soft tooling masters, display/concept models and finished components.

SLS

(Selective Laser Sintering)

This additive manufacturing layered process, using nylon and glass-filled nylon powders to produce functional and robust prototype components, is a cost-effective, accurate and rapid way to prove concepts and create low volume toolless usable components. The maximum single build envelope is 400mm x 280mm x 330mm. Alternatively, significantly larger parts can be produced by assembling multiple sections of components.

Machining

  • Prototype and low volume components machining (Qty. 1 to 20)
  • 5 Axis Machining (±02) for Aluminium and Metallics
  • 3 Axis (±15) Engineering plastics, tooling boards (PU & Epoxy) and performance foams.

Production of Master Patterns, Holding Fixtures, Composite tooling and Jigs for a wide variety of sectors including Automotive and Foundry work.

Vacuum Casting

Vacuum Casting is good for prototyping and low production volumes (Qty. 30 to 50)

Silicone tooling is produced using a master (3D printed or free issued) to create a cavity, in which vacuum cast resins are mixed and gravity-fed into the mould cavity under vacuum – this eliminates porosity and air voids and provides an excellent finish. A wide selection of grades can be chosen to mimic the production intent polymer, including for Nylon, Glass Filled Nylon, ABS, PP, Clear PC/ABS (including tinted) and TPE & Silicone Rubbers of various shore harness.

Metal Fabrication

Metal Fabrication for Prototyping and High-Volume production.

Sheet metalwork of gauges 0.5mm to 18mm in a wide variety of material grades including Aluminium, Mild Steel, Stainless Steel and Brass.

Processes include – Laser Cutting, Folding, Welding, Milling, Machining, Polishing, Powder Coating & Assembly.

Finishing

Whether it be wet painting, powder coating, part preparation or polishing, we have an in-house team of experienced craftsmen.  We also collaborate with an extensive network of trusted and skilled teams who support us regularly with the finishing of your product.

Injection Moulding

(New Project Development and Production Sourcing & Project Reshoring Consultancy).

  • Component design
  • Tool Design and Manufacturing
  • Polymer selection
  • Injection moulding production
  • Low Volume Injection moulding & Prototyping
  • Part testing & Measurement
  • Injection moulding reshoring (bringing project and tooling back to the UK industry).

CAD / CAM

  • CAD design and Model creation
  • Reverse Engineering
  • Component modification
  • CAD simulation
  • CAD model rendering
  • Tool Design
  • 3D Scanning
  • Dimensional reports

Media

Coming soon…