Manufacturing Services

Our experience of different manufacturing technologies means that we can utilise the most appropriate manufacturing process for each component. We take full advantage of automated or computer driven equipment to produce components in the most efficient way.  We also use traditional manual skills in our model making and so use the best and most efficient processes to create the models that our customers need.

As discussed in our DESIGN page, the component information created in our CAD system can be used to seamlessly drive manufacturing processes. This reduces error, improves quality and improves efficiency. Here are some of the processes that we use:

  • Machining: CNC (Computer Numerical Control) usually involves cutting out a 3 dimensional component from a plastic or metal solid workpiece. We create a 3D model of the finished product (as well as a traditional drawing), this is then used directly to program the toolpaths on the machine tool.  This method of information transfer conveys the finished component design clearly and quickly, ensuring greater accuracy and speed of production. This is great for producing batches of components as well as complex one-off components.
    A CNC Machining centre control panel with the CNC machine in the background showing how Forge Model Works uses advanced manufacturing technology for production
  • Turning: is essentially revolving a 2 dimensional profile around a rotating workpiece.  As with machining we take a 2 dimensional profile and use that as the basis for the turning process.  With both turning and machining the data used for programming can also be easily used to check compatibility with available cutting tools, tool shapes and clearances.
    A computer aided design model of a pair of locomotive driving wheels on an axle created by Forge Model Works showing how computer aided design is used to drive manufacturing processes.
  • Laser cutting: For laser cutting we generate a 2 dimensional flat profile, for wood, metal or plastic, and use this to set up a toolpath for the laser to follow and cut the material. The component profiles are also used to ‘nest’ the components on a virtual sheet of material and so optimise the utilisation of the material.
    A close up view of a laser cutter cutting head processing plywood
  • 3D printing: There are two useful types of  3D printing:
    Fused Deposition Modelling (FDM) where objects are built up layer by layer from extruded plastic.  We do use that technology but prefer the better definition and surface finish of stereolithography.
    A close up of a Fused Deposition Modelling (FDM) machine showing how Forge Model works uses advanced technologies for manufacture

Stereolithography (SLA)

  • which cures layer of liquid resin using a laser.  The system we use can print layers down to 0.025mm thickness (1 thousandth of an inch) which creates highly detailed models with effectively a smooth finish.
A Stereolithography (SLA) 3D printer demonstrating the technology used by Forge Model Works to create accurate and highly detailed model railway models

We may need to manufacture components as part of a larger modelling project or your requirement may be just for an individual component or components.  Either way we have the flexibility to deliver what you need.