Manufacturing & Assembly, Value Engineering

3 Steps: From Prototyping to Production

Optimas | November 8, 2022

Not only do Optimas supply fasteners and components to many different sectors, from automotive to agriculture, but we also design, prototype and manufacture quality parts for our customers. 

Using specialised equipment like 3D printing and bar turning, our in-house design engineers work with customers from product development to production line to make sure their parts are optimised for use, before being manufactured at our state-of-the-art cold-form facility in Droitwich.  

Here are just three steps we take to develop and produce high-quality fasteners:  

 1. 3D Printing 

Optimas’ expert design engineers work to industry-specific requirements with customers on-site or on a project basis to create reliable fastening solutions.  

3D printing is one way engineers can rapidly check the design and dimensions of a fastener outside of its application. 3D printers can prototype custom parts in as fast as a day, meaning it’s a highly efficient process. 

3D printing also allows for step-by-step product assembly, allowing increased visibility into each aspect of the design process. Manufacturers often require specialised parts, and 3D printing allows designers to create precise, geometrically complex prototypes. 

Prototypes created by 3D printing are also tangible and fully functional to accurately determine a part’s application suitability, and therefore optimise its design. If that part is deemed unsuitable, a new prototype can be printed by the next day.

3D printing is also cheaper than traditional prototyping methods, as it requires very few human resources, and the very little waste that is produced can be fully recycled. 

2. Bar Turning

After optimising a product’s design through 3D printing, the part can then be rapidly prototyped at a low volume through bar turning.  

Bar turning provides important information about a part’s mechanical properties, including its tensile strength, yield strength and ductility, to make sure it will perform well and without defects in its point of use.

Not only does bar turning achieve efficient and accurate prototyping, but it comes with no tooling costs for low volume parts. 

Bar turning also boasts high surface quality and precise dimensions, avoiding excess machining later on in the production process. 

Our engineers are certified by IATF 16949 and ISO 9001: 2015, and use quality planning systems to effectively diagnose, correct and mitigate process or product risk throughout the production process. 


3. Cold Form Manufacturing 

Once a part is optimised via this rigorous testing process, they can then be manufactured at a high volume at our specialised cold-form facility 

Cold-form manufacturing produces especially durable fasteners on a large scale, and an experienced cold-form manufacturer can work as accurately as within 0.02mm, meaning you’re guaranteed to receive specialised, high-quality parts, mapped exactly to your design. 

We have over 90 years’ experience in meeting our customers’ custom fastening requirements. Our integrated engineering and manufacturing capabilities can help you improve your product output and quality.

Contact us to maximise your production efficiency.