Prototype production
From idea to working prototype - and the first production run
3D printing, electronics integration, and vacuum forming in one workshop. We take your product from CAD to a tested prototype to low-volume production - no juggling separate suppliers.
Our work
Real parts 3D printed in our workshop, from functional brackets to multicolor promotional keychains.
One workshop for the whole prototype
Most prototypes need more than printed plastic. A product enclosure has to house a PCB, route cables and sensors, take a formed cover, and survive real use - then be repeatable when you need ten or a hundred. Send3DSend brings those steps together: we 3D print the structural parts, integrate the electronics, vacuum-form covers and casings over printed molds, and run small production batches of the finished design. One point of contact, one set of tolerances, faster iterations.
Related: rapid prototyping for quick test parts, 3D scanning to digitise an existing part, and our full materials range.
What we integrate
Four capabilities, one finished prototype
3D printing (FDM & SLA)
Structural parts, housings, jigs, and fixtures printed in engineering-grade FDM or high-detail SLA resin - the backbone of every prototype.
Electronics integration
Enclosures designed around your PCB: mounting bosses, cable and sensor channels, button and connector cut-outs, and assembly of working electronic prototypes.
Vacuum forming
Thermoformed covers, casings, and packaging shaped over 3D-printed molds - smooth cosmetic surfaces and protective shells without injection-mold tooling.
Low-volume production
Once the prototype is proven, we produce repeatable small batches - from tens to hundreds of units before you commit to mass production.
Built for hardware that has to work
Hardware startups
Turn a concept into a demo-ready, functional unit for investors, pilots, and user testing.
Custom enclosures
A precise housing for your existing electronics, sensors, or controller - fitted, not improvised.
Presentation models
Cosmetic, paint-ready prototypes with vacuum-formed covers for trade shows and product photography.
IoT & smart devices
Connected products that need a custom enclosure, sensor mounts, and a cosmetic cover around a working board.
How it works
From CAD to batch in four steps
Concept & CAD
We refine your idea or CAD into a manufacturable design - DFM review for printing, electronics fit, and forming.
Print the parts
Structural components printed in FDM or SLA, fit-checked against your electronics and assembly.
Integrate & form
Electronics mounted and wired, vacuum-formed covers and casings shaped over printed molds, full assembly.
Low-volume production
We lock the design and produce repeatable small batches of the finished prototype.
Common questions about prototype production
What is prototype production?
Prototype production turns a product idea into a working, testable physical unit and then manufactures it in small repeatable batches. At Send3DSend it combines 3D printing (FDM and SLA), electronics integration, and vacuum forming in one workshop, so your prototype goes from CAD to low-volume production without switching suppliers.
Can you integrate electronics into a 3D printed prototype?
Yes. We design enclosures around your PCB with mounting bosses, cable and sensor channels, and connector cut-outs, then assemble a working electronic prototype. It is ideal for IoT devices, sensors, and connected hardware.
What is vacuum forming used for in prototyping?
Vacuum forming thermoforms a plastic sheet over a 3D printed mold to make smooth covers, casings, and packaging. It gives a cosmetic, presentation-ready surface and protective shells without the cost of injection-mold tooling, which suits prototypes and short runs.
Can you produce a small batch, not just one prototype?
Yes. Once the prototype is proven we run low-volume production: repeatable batches from tens to hundreds of units, so you can launch or fulfil early orders before committing to mass production.
How much does prototype production cost?
Cost depends on part size, materials, electronics, finishing, and quantity. Send us your CAD and requirements and we will scope the whole project and reply with a quote.
Have a prototype to build?
Tell us about your product - electronics, enclosure, finish, and how many units you need. We'll scope it end to end.
Discuss your project