MANUFACTURING PROCESSES
3D PRINTING
The continual advancement of additive manufacturing brings many advantages to the product design space. At Orbital Creations we have deep experience in commercial 3D printing, as well as the prototyping of parts using this method.
We offer a range of engineering plastics, to create small to medium production runs of products that are ready for in field use.
Unlike plastic injection molding, 3D printing requires no tooling, making it a cost effective solution for producing plastic parts, especially when frequent design changes are expected or when tooling costs would be prohibitive. This flexibility makes 3D printing ideal for prototyping, low-volume production, and complex geometries that would be challenging or uneconomical to mould.
When time is limited and you need to see your first products as soon as possible, 3D printing could be the answer. Whatever your product, we will discuss this option in addition to our other production techniques.
As a cornerstone of mass production, plastic injection may be the best solution to scale your product delivery. Initial tooling lead time and cost is more than for other processes, but when quantity, form, unit cost and actual production time counts, this tried and trusted process is hard to beat.
Unit cost may be a fraction of other manufacturing processes, making this solution ideal for components where the design is locked in and parts will be produced for a long period of time.
Our established relationships with expert plastic injection suppliers who offer in-house mould making, will help your investment bear fruit for many years to come.
CNC MACHINING
For the best tolerance and repeatability in metal components, CNC milling and turning offer a reliable solution for parts of varying shapes and complexity.
Parts can be fully CNC-machined from solid stock, or undergo secondary machining, such as surface refinement or hole alignment after processes like casting.
Where required, stainless steel and aluminium parts can be brushed for a matte finish, while the latter may also be anodised for a natural or coloured appearance, with improved surface protection.
Compared to processes like die casting, CNC machining requires minimal or no tooling investment, making it ideal for low to medium production volumes or where design changes are frequent. While cycle times per part may be longer, the flexibility and accuracy of CNC machining could outweigh the trade-offs.
METAL FABRICATION
General metal fabrication encompasses cutting, bending, forming, welding and riveting of steel and aluminium components.
Our trusted fabrication partners work with a wide range of materials, including sheet metal, hollow tube, pipe, plate, and laser-cut parts, precisely shaped and assembled to meet our design specifications.
Where in-house powder coating is not available, we coordinate with third-party providers to ensure a high-quality finish. Some of our suppliers also offer integrated coating services, robotic welding and CNC bending for streamlined production.
For larger assemblies such as frames or sheet metal based products, metal fabrication combines components into robust products.
Laser cutting provides unmatched flexibility and precision for producing complex shapes in sheet metal and tube.
We use advanced 3D CAD software to design sheet metal components in their final bent form. From these, accurate flat patterns are automatically generated, ready for laser cutting with zero error and maximum efficiency.
Our expertise in sheet metal design ensures every part is not only visually refined and functional but also optimized for manufacturability, both at the laser cutting stage and during subsequent fabrication.
We can also coordinate powder coating services to deliver a durable, high-quality finish that enhances appearance and longevity.
DIE CASTING
Die casting is the metal counterpart to plastic injection molding—ideal for producing high volumes of precision parts in aluminium, magnesium, or zinc alloys.
While the initial tooling investment is higher, die casting offers excellent repeatability and is best suited for large-scale production where design changes are unlikely. It’s particularly advantageous for manufacturing complex geometries with tight tolerances and consistent quality across thousands of units. Part size may be a determining factor for investing in tooling.
For steel parts, other casting processes such as investment and sand casting are available.
EXTRUSION
Extrusion is the ideal process for producing long lengths of aluminium or PVC components with a consistent cross-sectional profile. It is particularly suited for shapes that are impractical or uneconomical to machine or cast, including sections with complete internal boundaries.
The material is pushed through a custom die, much like pasta, forming continuous profiles with precise geometry. Compared to plastic injection molding, extrusion tooling is more affordable, especially keeping in mind the long component lengths produced.
Minimum batch quantities usually apply, often resulting in substantial total lengths, so warehousing and inventory planning are important considerations.
Our expertise in extrusion design, combined with reliable partners offering in-house toolmaking, ensures we deliver high quality aluminium and PVC extrusions with excellent dimensional accuracy and surface finish.
TIMBER FABRICATION
We bring industry experience in designing modern, stylish timber-based components, ideal for integration into furniture, retail fit-outs, or large assemblies.
Our preferred substrates include MDF, HDF, and HDPB, with solid timber available upon request for projects requiring natural wood aesthetics.
Using our in-house 3D design capabilities, we engineer precise geometries and export production-ready files to trusted manufacturers equipped with CNC timber machining. This ensures accuracy, consistency, and a streamlined transition from design to production.
Final finishing options include lamination, natural veneer, or two-pack painting, allowing for a tailored aesthetic that complements both form and function.