3D Printing that solves real problems

What we do

Mitchell & Son Additive Manufacturing exists to solve problems that stop work. Most customers do not come to us because they are curious about 3D printing or want to experiment with new technology. They come to us because something has failed, something has broken, or something critical can no longer be sourced. Across Southampton, Hampshire, and the wider Solent and South Coast, we regularly deal with situations where downtime is costing money and production cannot simply wait for a supplier to respond. Emergency 3D printing, when applied properly, allows businesses to keep moving while longer-term solutions are considered. Our focus is not on novelty prints or visual models, but on functional parts that fit correctly, handle real loads, and survive real operating conditions. Every job starts by understanding how a part is used, what forces act on it, and what environment it lives in, because without that understanding, the print will fail again.

A large part of our work involves replacing components that were never designed to be replaced individually. Plastic clips, brackets, housings, covers, guards, mounts, and spacers often fail first, yet are bundled into much larger assemblies or discontinued entirely. For maintenance teams and procurement managers, this creates a costly problem. Injection moulding tooling is expensive, lead times are long, and minimum order quantities rarely make sense for a single failed part. Using additive manufacturing, we can replicate and redesign those components quickly, without tooling, and without committing customers to unnecessary volumes. We work from broken samples, partial parts, photographs, or measurements, rebuilding the geometry in CAD and correcting weaknesses where needed. This approach is used daily for manufacturing, transport, marine, restoration, and general engineering clients throughout Southampton, Portsmouth, Fareham, Winchester, Basingstoke, and surrounding Hampshire areas.

Material choice is one of the most important decisions we make, and it is never guessed. ABS, PETG, nylon, and reinforced engineering plastics all behave differently under load, heat, UV exposure, and repeated movement. ABS is strong and durable but will degrade outdoors over time. PETG offers improved UV resistance and flexibility. Nylons provide strength and wear resistance where movement and friction are involved. Reinforced materials are used where stiffness and dimensional stability matter. We explain these differences clearly so customers understand why a particular material is recommended and what trade-offs exist. For emergency replacements, the goal is often to restore function quickly without creating another failure point. Where parts are expected to remain in service long-term, durability and lifespan are prioritised instead.

Emergency 3D printing only works when speed and accuracy are balanced. Producing a part quickly that fails shortly after installation helps no one. For that reason, we always ask how a part is used, how often it moves, and what happens if it fails again. Infill percentage, wall thickness, print orientation, and material selection all affect strength and cost. A part printed at low infill may look fine but fail under load. A part printed solid will be stronger but uses more material and time. These decisions are explained upfront in plain language so maintenance managers and engineers can make informed choices. Our quoting process is straightforward, honest, and focused on getting the right result rather than the fastest possible output at any cost.

For procurement teams, predictability matters. Short-run production is handled with consistency so repeat orders behave the same way each time. Once a part has been proven in service, producing replacements becomes quick and reliable. This is particularly useful where legacy equipment is still operational but no longer supported by the original manufacturer. Additive manufacturing allows businesses across Hampshire and the South Coast to extend the life of assets without redesigning entire systems. It also allows design improvements to be made incrementally, addressing known weak points without committing to full retooling. This flexibility is one of the main reasons emergency and industrial 3D printing has become a practical manufacturing tool rather than a last resort.

Based in Southampton, Mitchell & Son supports businesses throughout the Solent region that need fast, sensible manufacturing solutions. Injection moulding has its place, but the upfront costs often run into thousands before a single part is produced. For low-volume, emergency, or discontinued components, additive manufacturing is often the only commercially sensible option. We also offer post-processing where required, including sanding, surface finishing, and reinforcement, to improve durability or appearance when needed. These services are optional and applied only where they add real value. The objective is always the same: produce a part that works properly, fits correctly, and does its job without becoming the next problem.

Everything we do is driven by real-world use. If a part is ornamental, it can be produced cheaply and quickly. If a part is handled daily, subjected to force, or critical to safety, it is built accordingly. We do not oversell materials or processes that are unnecessary, and we do not underspec parts that will fail prematurely. This approach has allowed us to support manufacturers, engineers, restorers, and maintenance teams across Southampton and Hampshire with solutions that make practical and financial sense. When something breaks, the priority is getting it working again reliably, not experimenting with technology for its own sake.

If you are dealing with a breakdown, an obsolete component, or a supply issue that cannot wait, emergency 3D printing provides a fast and flexible solution. By combining practical experience, CAD capability, and material knowledge, we are able to produce functional parts without the cost and delay of traditional manufacturing methods. This is what we do every day, and it is why customers return when the next problem arises. The goal is not just to print a part, but to solve the problem that caused the failure in the first place.

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