Prototyping & ONE-OFFS

Not every product is suited to conventional manufacturing. When dedicated production tooling cannot be justified, either technically or economically, prototyping provides an efficient way to develop, validate and produce functional solutions.

Explore a selection of projects below.

Dual Vise Locking System

A compact locking mechanism developed for a CNC machine vise carousel, allowing two vises to be securely clamped while mechanically interlocking the drawer.

CHALLENGE

A compact locking mechanism was required to securely hold two CNC vises during workpiece clamping while preventing them from returning to the carousel in the locked position.

APPROACH

Designed in CAD and validated with a fully 3D printed prototype, the final mechanism combines laser-cut, welded, CNC machined and 3D printed components. A single locking action secures both vises while preventing the drawer from returning to the carousel.

RESULT

A compact and reliable solution that enables secure workpiece loading, streamlines the loading process and prevents incorrect operation of the automatic vise exchange system.

Demonstration of the loading sequence. The vises move freely until secured to the baseplate using the same socket wrench used for workpiece clamping, providing a stable platform for tightening the workpieces.

Underside view demonstrating the locking mechanism. A single movement secures the vise to the base and engages the integrated interlock that prevents the drawer from returning to the carousel.

tube recess tool

An expandable internal forming tool developed to create a precise recessed area in rectangular steel tubes for flush-mounted dome stickers.

CHALLENGE

Create a consistent recessed surface in rectangular tubing while preventing distortion of the tube during the forming process.

APPROACH

A CAD model was developed and validated using a carbon fibre reinforced 3D printed prototype with an internal wedge expansion mechanism. After functional testing, the design was strengthened with laser-cut steel reinforcement plates and precision locating features to ensure accurate positioning inside an external forming fixture.

RESULT

A durable forming tool capable of producing repeatable recessed areas for dome stickers, enabling low-volume production without deforming the tube.

CaM SLIDER MECHANISM

Cam slider mechanism for accurate logo application.

CHALLENGE

A mechanism was required to ensure the product returned to the same angular position after a 180° rotation, allowing both sides to be pad-printed consistently.

APPROACH

The concept was developed from hand sketches into a CAD model, followed by rapid FDM prototypes to validate the mechanism. The final prototype was produced using SLA printing to achieve the dimensional accuracy required for the bearings and linear guidance.

RESULT

A smooth and repeatable cam slider mechanism that consistently returns the product to the same position after a 180° rotation while automatically actuating the pad printing cycle on every forward stroke.

Demonstration of the complete mechanism during production. The forward stroke actuates the pad printer, while the return stroke rotates the component through 180°, preparing the opposite side for the next print cycle.

A very small needle roller bearing acts as the cam follower, running in the cam slot to provide accurate, repeatable positioning while significantly reducing wear.

Radius Forming Tools

A cost-effective forming solution for a one-off aluminium duct, using temporary FDM-printed tooling to produce multiple bend radii.

CHALLENGE

A compact installation space required several different bend radii. Dedicated tooling was not economically viable for a single component.

APPROACH

The duct was designed in CAD before a series of FDM-printed radius formers was produced to accurately shape each aluminium section prior to welding.

RESULT

A practical forming solution for a one-off component, combining CAD, FDM tooling and fabrication to achieve the required geometry.

Flexible machine sleeve

A 3D-printed replacement sleeve for a discontinued part.

CHALLENGE

The original protective sleeve was no longer available. The new part needed to ensure a precise fit, high flexibility, wear resistance, and resistance to various coolants.

APPROACH

A suitable material was selected, and the part was designed in CAD. The first two ribs were printed to validate material flexibility and fit before refining the design and producing the final part.

RESULT

A fully functional prototype that fits perfectly and now serves as a direct replacement for the original part.

Moto Industries supports the development of functional prototypes and one-off products by combining CAD design with a range of in-house manufacturing processes, including 3D printing, vacuum forming, pad printing, engraving, injection moulding, fabrication and assembly.