3D Printing Service

Case Study: Southampton
Precision Prototyping & Emergency Turnaround for Aerospace Sub‑Assembly

Project Title: Emergency replacement for a lightweight duct manifold in a UAV test rig at Eastleigh Aerospace Park

Client: A small aerospace component manufacturer located in the Southampton / Eastleigh cluster, supplying UAV subsystems to OEMs across southern England.

Local & Industry Context:
Southampton, as a port city with a strong engineering heritage and proximity to aerospace and maritime engineering firms, is a natural base for advanced manufacturing services. Eastleigh and the surrounding business parks host suppliers for aviation, defence, marine, and automation. In that environment, downtime in a rig can cascade delays across test schedules and certification timelines. A provider like Mitchell & Son, offering industrial 3D printing, reverse engineering and rapid prototyping from within Hampshire, is positioned to deliver value by bridging speed, accuracy, and flexibility. Our “Emergency Prototyping” and “Manufacturing 72” paradigms are directly aligned to the needs in such settings.

The challenge — When the bespoke manifold goes wrong, and tests await

The client had constructed a small UAV test stand with a custom air‑duct manifold that channels cooling air to multiple avionics modules.

That manifold had features like internal branching, variable cross sections, and integrated mounting lugs. It was originally CNC‑machined from aluminium, but due to a geometry change in the avionics layout, the part was modified and remade in plastic for quicker iterations.

On the day before a major test campaign, one of the duct arms cracked near a junction because of vibration fatigue. The original part was an in‑house job, meaning no external supplier could reprint it at short notice. Even within the client’s own shop, lead time to recut it by CNC was projected at 7 full days, which would push the test schedule and impact contractual deadlines.

The geometry was too complex for off‑the-shelf duct fittings; airflow internal surfaces had to meet smooth curvature, minimum pressure drop, and have mounting features precisely aligned. So, the client reached out to Mitchell & Son (who advertise coverage across Southampton) for an emergency solution. mitchellsson.co.uk

Our response — Rapid CAD, parametric refinement, and high‑quality polymer prototype

1. Rapid mobilisation & data gathering

Because the client was local (Southampton / Eastleigh), we were able to dispatch an engineer within hours with a portable 3D scanner to capture the cracked part and its mating environment (adjacent assemblies, bolt holes, alignment surfaces). Meanwhile, the client emailed us their original CAD sketches and interface constraints.

We performed a quick triage to confirm that the part fit within our “Manufacturing 72” size and quantity envelope (i.e. small enough, few units) and that a polymer replacement would be acceptable for test use (i.e. non-structural, non-pressure).

2. Reverse engineering, parametric redesign & optimisation

From the scan and client interface data, we constructed a full parametric CAD model in Fusion 360. But we didn’t just copy — we had a window to improve:

• We smoothed internal duct transitions to reduce turbulence.
• Introduced rounded internal radii to ease airflow.
• Mounting fillets and ribs were added to reduce stress concentration at the cracked junction.
• Introduced alignment features to permit plug‑and‑play assembly with existing mating parts.

We shared incremental previews with the client, asking for confirmation on critical interfaces (flanges, bolt holes, orientation) before finalising.

3. Material selection & test coupon

Given this is a UAV test rig, temperature exposures are moderate, vibration is significant, and surface finish matters for airflow. We chose ASA (UV-stable, good mechanical strength) with a thinner skin thickness in non-critical areas. For the internal duct surfaces, we produced a small printed test coupon with the same internal radius to check surface smoothness and airflow performance (i.e. check flow friction by visual inspection). The coupon was printed clean, with minimal surface ripple, and the geometry fidelity was within ±0.1 mm tolerances.

We also considered Nylon + carbon fibre composite (through partner processes) for a higher strength option, but for the urgency, decided ASA would do the job for test use; we reserved the composite option later for the production version.

4. Printing, supports & post‑processing

We oriented the part to minimise internal support obstruction (i.e. printing arms upright, supports external where possible). We used 0.15 mm layer height for better surface fidelity, ~45% infill for stiffness, and solid skin layers. After printing, we removed supports carefully, sanded flange faces, and applied a thin coat of epoxy resin on the inner duct surfaces to smooth microporosity and reduce flow roughness.

We dimensionally inspected critical interfaces (bolt hole diameters, flange flatness) with a calliper and CMM probe, comparing them to the CAD model.

5. Delivery, fit test & validation

The next morning, our technician delivered the part to the client in Southampton / Eastleigh and helped install it. It aligned perfectly, bolted into place, passed preliminary pressure and flow checks, and allowed the test rig to go live as scheduled — avoiding the 4‑day delay that would otherwise have occurred.

We operated on a tight feedback loop: the client ran two test cycles. A minor interference with a cooling hose was spotted; we revised the CAD by +0.7 mm clearance and printed a quick insertion patch, which slotted into the manifold and corrected the interference within hours.

Why this works in the Southampton cluster

• Proximity matters: Being in Hampshire means we’re reachable quickly. For a test facility in Eastleigh or Southampton, a vendor in Kent or further afield would likely incur shipping delays.
• Aerospace mindset: We understood tolerances, flow surfaces, lightweight design — not just generic 3D printing.
• Adaptive redesign: We didn’t just copy; we improved, giving the client confidence.
• Iterative support: We stayed until the part worked, not just “you get your print, bye.”
• Local trust & network effect: In the Southampton engineering cluster, word-of-mouth is powerful — being known as “that rapid prototyping shop just down the road” is a strategic advantage.
• 
  

Lessons & best practices for clients in the Southampton / aerospace space

1. Capture a scan early — even preliminary scans help validate whether a replacement is feasible.
2. Embed adjustability in CAD — make sure bolt holes, alignments, and offsets are parameterised so minor tweaks are trivial.
3. Aim for smooth internal surfaces — in ducts or fluid systems, reduce turbulence by post-processing (resin coating, sanding).
4. Use test coupons (miniature replicas) — quick test pieces validate geometry and finish before full print.
5. Retain the CAD file — having the digital twin from day one avoids future data loss.
6. Build in spare units — for test rigs or prototypes, printing one or two extras concurrently costs little relative to the risk of failure mid-test.

“Very helpful guys, patient too. Had a cool design to print a custom backplate for my Legion Go handheld device, and these guys stepped up and delivered! Great communication and prompt delivery once the print was successful. Of course, the backplate fits perfectly, even clicks into place. Printed using PETG at a very competitive price. I highly recommend them!” — Mickey Padge

“I needed some very small plastic shelf support brackets that were no longer provided by the manufacturer of my old SieMatic kitchen units. Mitchell & Son Design were approached and produced a 3D model and then 3D printed the brackets very quickly, and to an excellent standard. I highly recommend their service and expertise.” — John Watkins

“Posting on behalf of my father. He had four dust caps made for some Girling brake cylinders for a 1950s Riley 2.5 ltr. They were perfect, spot on. Definitely recommended.” — David Ballantyne

“A very nicely made part and these guys are easy to deal with, planning the next job right now.” — Barrie Lever

“Very professional service resulting in a near absolute duplicate of the original fastener. The first batch printed were very marginally larger at 3 mm which the company identified, made us aware of and then immediately re‑printed, correcting the error. You could not really ask for more.” — Verified reviewer (Checkatrade)  Checkatrade

“Quick and efficient service, good quality product within specification.” — Verified reviewer  Checkatrade

“Amazing level of service. Really quick response.” — Verified reviewer  Checkatrade

“ I wanted to take this opportunity to thank you for the great work you did on the 20 face masks for a friend of ours who is a nurse at a major hospital. They desperately needed some PPE face masks… When we received the face masks, they are nice and sturdy. I am so pleased that we were able to meet our friends’ needs. Thank you so much. ” — Nigel

How to get Emergency 3D Printed Parts Manufactured

in Hampshire

Need a critical part made and delivered within 72 hours across Hampshire?
We’ve got your back.

If you’ve had a component fail — a guard, a bracket, a duct, or even just a cap that’s holding up the line — we triage fast, reverse-engineer or CAD up the part, print it in strong industrial-grade plastic, and get it delivered or ready for pick-up.

Whether you're in Southampton, Portsmouth, Basingstoke, Winchester, Fareham, Andover or anywhere nearby, we’ll sort it.

How it works – step-by-step:

1. We triage the job within an hour – Just call or WhatsApp me. Send me a photo and some rough sizes, and I’ll tell you straight away if we can do it. If you need help measuring or scanning, I’ll come out and scan the part on-site (within reason – if it’s the size of a cow, give me a heads up).
2. We CAD or scan the part – I either 3D scan the old one, or I redraw it in CAD from your photo or sketch. You don’t need to be a CAD wizard – I’ll sort that.
3. Material selection – I don’t just print in any old stuff. I’ll match the plastic to your environment. UV exposure? Oil splash? High vibration? We’ll get it right.
4. We print it – Next-day dispatch for smaller FDM jobs (up to 150x150x150mm, max 5 parts if you confirm and pay by 12 pm).

If it’s SLA or MJF, we use our partners. SLA takes 3-5 working days. MJF Nylon about 7–10 days.

5. Quality check and fit – We do a visual check and key dimension check. If needed, I’ll even come out and do a fit test.

6. Delivered fast – Local bike courier or same-day van. You can collect if you like. Out-of-hours available by agreement – just ask.

Who’s this for?

If you’re in aerospace, automotive, motorsport, food packaging, electronics or just general manufacturing,

 And you’ve got jigs, brackets, covers, mounts, change parts, or anything else non-structural that’s failed – this is for you.

We also work with MRO teams and machine builders who need stuff like tooling aids, spacers, caps, or temporary replacements.

What qualifies for Manufacturing 72?

• Size: Max part size for next-day service is 150 x 150 x 150mm, and up to 5 parts in a batch. Just make sure you approve and pay by 12 noon.
• Materials: We print in ASA, ABS, PETG (for UV resistance), and can offer SLA resin (Tough or Clear) and MJF Nylon 12 through partners.
• Other industrial polymers available on request.
• 
  
• Use Cases: These parts are for non-pressure, non-load-bearing use – so guards, covers, brackets, housings, sensor mounts, and that kind of thing.
• Not suitable for: Pressure vessels, structural load-bearing components, or safety-critical parts. We’ll be straight with you if it’s a no-go.
• 
  

Prices (no fluff, just facts):

• FDM (Next-Day Plastic): from £25
  Good for quick turnaround. Up to 5 parts, 150mm size limit, dispatch next working day if ordered by 12pm.
• 
  
• SLA Resin (Partner Service): from £30
  Takes 3–5 working days. Can be expedited for +15% if you’re in a pinch.
• 
  
• MJF Nylon 12 (Partner Service): from £30
  For strong, precise parts. Takes 7–10 working days. Again, +15% if you need it faster.
• 
  

Specs and tolerances (because it matters):

• FDM: ±0.3% or ±0.2 mm. Layer height between 0.15mm and 0.3mm.
• 
  
• SLA Resin: ±0.2% or ±0.1 mm. Smooth finish.
• 
  
• MJF Nylon: ±0.3% or ±0.3 mm. Bead-blasted finish.
• 
  

Final tolerances and finish will be confirmed when we quote – depends a bit on the geometry and use case.

Quick example – Conveyor guard for FMCG line:

One of the clients had a snapped conveyor guard. No spares in sight, and the original tool had been lost years ago.

We scanned the cracked part, redesigned it with a bit more strength, printed it in ASA, and had it on their desk within 72 hours.

They were up and running again without retooling. No drama.

Cut-off Times:

• FDM: Approve and pay by 12:00 → dispatch next working day.
• SLA: 3–5 working days (expedite +15%).
• MJF: 7–10 working days (expedite +15%).
• 
  

CAD + Reverse Engineering Service:

Don’t have a model? No problem. We’ll scan or CAD it from the sample or drawing.

Once we’ve got the 3D model, you can have a copy if you like – it’s your part after all.

If we need to travel for on-site scanning, that might add a bit to the lead time.

 We'll let you know upfront.

Extra Options (if you want to get fancy):

We also offer post-processing:

• Sanding
• Priming
• Resin-coating
• 
  These add a bit to the cost, but the finish is much cleaner and stronger.
• I’ll be honest if it’s worth it or not for your job.
• 
  

Contact us now to get moving:

📞 Call Manufacturing 72 Hotline: 07876 131 539
💬 WhatsApp: Click here to message us
📧 Email: dwight@mitchellsson.co.uk

We’re not here to mess you around. If we can do it, we’ll do it fast and do it right.

If we can’t – we’ll tell you straight. What we offer is honest service, solid quality, and fast turnaround.

That’s what Manufacturing 72 is all about.