SLS - Selective Laser Sintering

“Functional high-strength components - without the need for tooling”

Hi-Q SLS Sinterstation

Automatically build functional parts, casting patterns and tooling inserts from your 3-D CAD data. Our HiQ Sinterstation system, representing the future of Instant manufacturing technology, directly produces end-use plastic or metal parts, tooling inserts, or casting patterns from your 3-D CAD data files. Eliminate the need for machining, tooling, casting or other secondary processes — saving you time and money.

Benefits of using the following SLS materials?

Nylon: NEW Superior Finish Innov’PA 1550

You can use/test your first off prototype without the fear of breakage.
Acts like moulded components. Strong and durable.
Excellent for fit and function. Ideal for clip features, living hinges and snap-fit connections.
Can build more complex structures than SLA as no supports are required.
The process can produce watertight components.
High chemical resistance. High Temperature resistance.
Durable patterns for sand casting.
Superior surface, straight from machine, compared to ... Duraform PA, GF, EX or EOS PA2200, or PA3200

For detailed material data sheet download here >>>>

Investment Casting Wax alternative: Castform™ PS,

Wax impregnated polystyrene masters for investment casting. Excellent for complex models with features that would prove awkward or impossible to mould from standard tooling. Malcolm Nicholls Limited have developed a method to improve the surface finish to that from standard Castform™ products, giving aesthetically pleasing castings as well as functional ones.

Different levels of finish available from straight off the machine to fully finished.

MNL Rapid Product Development Services…

SLA- Stereolithography

“From large frame machines using watershed resin to intricate detail produced on a viper”

Stereolithography is the most widely used rapid prototyping technology. It is generally considered to provide the greatest accuracy and best surface finish of any rapid prototyping process. SLA has a high resolution and is most commonly used as patterns for silicone tooling. Often sanded, painted, & tinted. Stereolithography is fast, allowing prototypes to be made in a matter of days, and the complexity of the model is seldom a factor.

Applications of SLA Technology include; Aesthetic & conceptual models. Parts requiring detail and accuracy. Master patterns for polyurethane castings. Quickcast™ investment patterns allowing rapid production of metal castings. Design evaluation models.

Large models are produced on a 5000 machine using Somos 11122 Watershed™ resin. The clear resin has properties that match ABS, one of the most widely used plastics throughout the manufacturing industry. Watershed™ is ideal for flow analysis models, waterclear models including lenses and lightguides. The resin is extremely durable making it excellent for snap fits. Its low water absorption means it is not affected by high humidity levels. It is also the resin of choice for Quickcast™ investment patterns for foundry use.

Small highly intricate models are produced on a Viper machine also using Watershed™ resin. The Viper in Hi-res mode utilises the lasers extremely small spot size of just 0.075mm to produce precise, crisp detail on even the most intricate complex parts.

For detailed material data sheet download here >>>>

We utilise our 40+ years of modelmaking experience to combine the two capabilities, producing large hybrid models with complex areas.

Different levels of finish available; from straight off the machine to fully finished.

Investment Casting

“From one off highly complex components - to batches of several hundred”

Regardless of size, complexity or quantity, we have a choice of processes to produce your prototype investment castings in most metals including; Aluminium, Zinc, Titanium, Steels, and magnesium. We specialise in producing the investment casting “waxes” and then subcontract out to a selection of foundries who have been specifically chosen for their material choice, quality and willingness to do prototype runs along side their production. So whether you require waxes for your own foundry purposes or metal castings, we have the right process for you.

Techniques on offer:

SLA Quickcast™ using Watershed™ 11120; Direct patterns from 3D data within 2-3 days. Ideal for medium to large components. Compatible with standard foundry practises, Watershed™ material is the best choice resin for QuickCast™. It has low ash content (0.035%) and low antimony content (0.021%). It also has an HDT low enough to ensure pattern collapse during burn-out preventing shell burst. Improved accuracy, surface finish and larger one-piece patterns are advantages over Castform™.

SLS Castform™ PS; Direct patterns from 3D data within 3-4 days. Ideal for medium sized highly complex components. Excellent for complex models with features that would prove awkward or impossible to mould from standard tooling. MNL have developed a method to improve the surface finish to that from standard Castform™ products, giving aesthetically pleasing castings as well as functional ones. Although ideal for 1-offs, depending on size, 100s of waxes can be produced in only a few days. Advantages over Quickcast™ include even lower ash content (0.02%) and supports are not required, perfect for internal coring etc.

Investment Casting Waxes from Silicone Tools This solution is perfect for multiple waxes, especially when quantities are unknown, as extras can be produced in hours. This cost effective route produces waxes with the best surface finish over all three techniques. The wax itself is standard foundry wax, thereby replicating the exact production environment.

“Parts can be produced in a wide array of materials to simulate most engineering plastics”

Masters from any source are used to produce silicon tools from which castings can be produced in a wide array of materials to simulate most engineering plastics.

We can produce PU castings in the following material simulants or properties: ABS, Polypropylene, Nylon, Glass-filled Nylon, Polycarbonate, TPE, Hytrel, HDPE, etc. Temperature specific materials, flexible materials with A Shore ratings as low as 30A up to 90A and D Shore ratings also. Most of the above are available in clear (with the notable exception of the high-temp one).

Silicone tools guaranteed to produce a minimum of 20 castings. (We will replace the tool at no cost should the tool break up prior to producing 20 parts) Tools are available in multi-cavity versions in order to produce larger quantities quicker and more economically. Metal inserts are used to hold tight tolerances in bores and critical areas etc. In these scenarios we have been known to hold tolerances as tight as ±0.05mm.

Typical applications are endless; however here are just a few areas where we have produced PU parts where our competitors couldn’t: Medical remote control handset with gloss finish, functioning multi-coloured flexible keypad and integrated built-in over-moulded seal, to provide a pressure-tested watertight seal.

Under-the-bonnet common rail fuel system component, combining high accuracy stepped bores (±0.05mm) with a high temp requirement of 120°C and a resistance to fuel, oil etc. The components excelled in the tests coping with 13 Bar of pressure.

Chrome effect parts. Parts to represent chrome plating are achieved using a mirror finished master and high temp PU castings which are subsequently vacuum-metalised.

Ladies disposable razor handle. This set of parts were required to be identical in their semi-transparency colour, perfectly edge-matched over-moulding and accurate to provide a perfect snap fit to the production made razor heads.