Crittall Windows Ltd approached Nexform with an urgent request to replicate a critical electrical switch component that was no longer available from their original supplier. The part was essential for operating a main switchboard within one of their warehouses, and without a working replacement the site faced significant operational risk. The client needed a faithful reproduction of the existing component, along with spare units to ensure continued reliability. Accuracy was vital. The replacement had to fit, function and perform exactly like the original, with no modification to the existing switchboard.
Nexform inspected the supplied sample and broke the assembly down into its individual parts. We used vacuum casting to replicate each component, selecting Task 4 two part plastic for its strength and dimensional stability. Two silicone moulds were created for the required parts, allowing us to produce high quality castings with tight tolerances. Each cast component was then hand finished to match the original geometry and surface detail. This combination of precise mould making, careful casting and manual refinement ensured the new parts behaved identically to the original switch assembly.
The final components were an exact match to the samples provided by Crittall. The client received fully functional replacements along with spare units to safeguard future operations. By recreating an obsolete part quickly and accurately, Nexform helped the warehouse avoid a potentially serious electrical issue and maintain uninterrupted control of its switchboard.
Bringing ideas to life through precise, functional, and visually impactful prototypes—designed to impress in both industrial and marketing settings.
Transforming validated ideas into high-quality, functional parts—delivered with speed, consistency, and precision across any volume.
Producing standout pieces that merge form and function—designed to elevate brands, enhance products, and make a lasting impression in any environment.
Used for bespoke signage, props, furniture, and structural elements, wood offers a natural, high-quality finish for a wide range of projects.
Ideal for creating complex, custom components, 3D printed plastic enables rapid prototyping and tailored solutions across many sectors.
Used for structural frameworks, durable components, and high-end finishes, metal provides strength and longevity across many applications.
Perfect for highly detailed, precision parts, 3D printed resins allow for intricate textures and finely tuned designs in various industries.
