Prototype & Pre‑Production

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How to deliver parts to your customer before your production machine is ready.

Due to supply chain issues, equipment lead times are too long, and you won’t be able to use your production machine to meet part delivery deadlines.

Extol can help you get parts fast, satisfy your customers, and start production on time.

  • Pre-production part builds. We support pre-production part builds in our lab. With our plastic welding experts and capable plastic welding equipment, you can make parts while your machine is still being built.
  • MJF 3D printing. We can also 3D print functional parts to save you even more time.
  • Fast validation. By welding parts fast, you can find issues and fix them prior to production, saving you time and money.

Contact us today to find out how we can help you meet your delivery deadlines.

We help you assemble prototypes and pre-production parts for various applications. Whether you have an automotive, life science, energy storage, or some other application, we’ve got you covered.

Check out these example applications.

Automotive

Dark car interior showing interior trim

Interior Trim

Center consoles, instrument panels, and other interior trim are often assembled with hot-plate welding, infrared welding, and staking with InfraStake or nanoSTAKE.

Closeup of a dark colored open glove box

Glove Boxes

Glove boxes are often assembled with hot-plate welding.

Closeup of a dark colored door panel

Door Panels

Door panels are often assembled with hot-plate welding, infrared welding, and staking with InfraStake or nanoSTAKE.

Closeup of a red taillight on a blue car

Taillights

Taillights are often assembled with hot-plate welding, laser welding, and staking with InfraStake or nanoSTAKE.

Closeup of a blue car with bright headlights

Headlights

Headlights are often assembled with hot-plate welding, laser welding, and staking with InfraStake or nanoSTAKE.

Closeup of an engine

Engine Manifolds

Engine manifolds are often assembled with spin welding, infrared welding, hot inserts, and vibration welding.

Closeup of a bright orange battery

Batteries

Batteries are often assembled with hot-plate welding, laser welding, infrared welding, and staking with InfraStake or nanoSTAKE.

top view of a fluid reservoir

Fluid Reservoirs

Brake and coolant reservoirs are often assembled with hot-plate welding.

Life Sciences

purple and white pharmaceutical filtration devices

Pharmaceutical Filtration

Pharmaceutical filtration components are often assembled with hot-plate welding, laser welding, spin welding, and infrared welding.

gloved hands working on a catheter with a syringe

Catheters

Catheters are often assembled with infrared welding and laser welding.

closeup of medical device

Medical Devices

Medical devices are often assembled with hot-plate welding, laser welding, infrared welding, and staking with InfraStake or nanoSTAKE.

closeup of microfluidics

Microfluidics

Microfluidics components are often assembled with hot-plate welding and laser welding.

Energy Storage

large flow battery

Flow Batteries

Flow batteries are often assembled with hot-plate welding, stack welding, laser welding, and heat sealing.

closeup of red and blue manifolds

Manifolds

Manifolds are often assembled with hot-plate welding, stack welding, and spin welding.

closeup of electronic device with two dials on each

Electronics

Electronics are often assembled with hot-plate welding, laser welding, and staking with InfraStake or nanoSTAKE.

 

Design

If you need help with your assembly’s welding or staking design, we offer guidelines for the best joint possible. We also analyze your design and give you application-specific recommendations.

3D Printing

For the fastest assemblies, we 3D print components using the Multi Jet Fusion process. These printed parts are strong, functional, and can be staked and welded just like molded parts. You can have parts in just days.

Prototype Tooling

We build prototype tooling that firmly supports and retains your parts for the welding or staking process.

Weld Parts

We weld your parts using the prototype tooling and the equipment we have in our lab.

Validate Parts

We validate the welded parts. We can perform tensile, burst, and leak testing.

Rent Equipment

If you prefer to weld the parts yourself, you can rent the equipment in our lab. You come to Extol, use a machine, and get priority access to one of our expert engineers for help whenever you need it.

The fastest way to get functional parts

Production molds and equipment take months to build before they start making plastic parts. When you are in a hurry, this is too long. You need functional parts fast to meet your deadlines.

Enter Multi Jet Fusion (MJF) 3D printing. MJF parts can be produced in days and are functional. That means they are non-porous and can be welded, staked, and assembled, just like molded parts.

By using MJF 3D printing with Extol, you can cycle through several design iterations in the same time it would take to get the first design off a mold.

Get parts faster, test more designs, and reduce lead time – all with MJF 3D printing.

Prototype timeline

Request a quote to get parts fast.

Tell us about your application and request a quote. Whether you want a few prototype parts or several hundred pre‑production parts welded, we’ve got you covered.

Let us know what you need.