Bidford-on-Avon, Warwickshire. Mon to Fri.01789 224228
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Prototype to production · stage one

First parts you can hold, test and show, quickly.

A hand-cast silicone mould from a 3D print or an existing object, and a small batch of parts in silicone or PU. It's the cheapest way to find out whether the design works before anyone commits to tooling.

The detail

Hand cast prototypes, at group level.

Hand-cast prototyping is where most of our programmes start. The tool is quick and inexpensive, the parts are real, and you learn more from ten parts in your hand than from any render.

We build the prototype with production in mind, so the lessons carry straight into the next tool.

Back to From first prototype to production volume, in planned…

Clear silicone being poured over a carved pattern in a timber mould box.

What's involved

Six parts of the work.

From a print or a sample

Masters from 3D prints, machined patterns or existing objects.

Silicone or PU parts

Material chosen to represent the production part as closely as possible.

Small batches

Enough for testing, photography, pitching or pilot customers.

Quick changes

A new tool for a revised design costs little and moves fast.

Production notes

What we learn about draft, fill and release is written down for later.

Weeks, not months

Quick turnarounds so the prototype keeps pace with your design.

Prototype development stages shown with masters, mould and cast sample parts
Prototype stages laid out from master to sample parts

How it runs

Four steps, in order.

  1. 01

    Master

    Your print or sample, or we make one.

  2. 02

    Mould

    Hand-cast silicone tool.

  3. 03

    Parts

    A small batch cast and finished.

  4. 04

    Learn

    Feedback captured for the next stage.

Is it right for you?

An honest fit check.

A good fit when

  • Your design is new and unproven
  • You need samples for a pitch, launch or crowdfunding
  • You want user feedback before committing to tooling
  • The design is still changing

Probably not the answer when

  • You need hundreds of identical parts now — see bridge tooling
  • The part must be production-grade LSR for certification testing
  • Rigid thermoplastic prototypes — 3D printing may be quicker

At a glance

The ideas in pictures.

Which route suits your quantity

PrototypesHundredsThousandsTens of thousandsPrototype toolingCompression mouldingTransfer mouldingSolid silicone injectionLSR injection

Swipe to see the whole diagram

A general picture. Shape, material and detail also decide the route, and we talk it through with you.

One enquiry, the right team

  1. 01One enquiryTell us what you need
  2. 02Right divisionWe bring in the specialists
  3. 03One quoteCovering every part of the job
  4. 04Named contactOne person keeps it moving
  5. 05DeliveredMoulds, parts or both

Swipe to see the whole diagram

You explain the project once. The Group team co-ordinates the rest.

FAQs

Common questions.

How close are prototypes to production parts?

Close in shape and feel. Surface and consistency improve with production tooling.

Can you make the master?

Yes. From CAD, sketches or an existing object.

Can prototypes be sold?

Often, yes, for early customers — just tell us so we choose the right material.

Related

The rest of this service.

Tooling for the gap between ten parts and ten thousand.

Your prototype worked and orders are coming, but full production tooling isn't justified yet. A bridge tool — improved…

Moving into production tooling — ours, or one you already own.

Whether you're commissioning a steel production tool from us or moving an existing tool from another supplier, the…

From first prototype to production volume, in planned stages.

Hand-cast prototypes, bridge tooling, then production steel — with a clear trigger for each step. You spend on tooling…

The group

Delivered across the group

This work is coordinated by TCI Group and carried out by whichever of the four divisions suits your part.

TCI GroupThe umbrella brand and single number to ring. You are here.TCI MouldingsCustom silicone and polyurethane moulds.TCI CulinaryFood-safe silicone for patisserie and confectionery.TCI ConstructionFormliners, GRC and precast concrete tooling.TCI ProductsOEM silicone and rubber at volume.
Prototype, bridge tooling and production tooling shown side by side
Planned stages from prototypes to production tooling

Get in touch

Not sure which division? Tell us what you're making.

Send us a sketch, a photograph, or a paragraph. We'll come back with the right division, the right route, and an honest sense of what it will take.

Send an enquiry 01789 224228

Real people, a real workshop

You deal with the people who make it.

No call centre and no middlemen. When you contact TCI Group, you speak to the team who design, build and check your mould.

  • A real Warwickshire workshopUnit 15, Waterloo Park, Bidford-on-Avon, Alcester B50 4JG.
  • Real people on the phoneCall the team on 01789 224228, Monday to Friday.
  • The same team on every jobDesign, production and aftercare come from the people you see here.
  • Five brands, one teamMoulds, culinary, construction and contract products, all run from Bidford-on-Avon. See the divisions.
The TCI workshop, with moulds on the bench mid-build.
The TCI workshop, with moulds on the bench mid-build.
The TCI design and project office.
The TCI design and project office.
A stack of TCI silicone moulds.
A stack of TCI silicone moulds.
  • Thomas LaneManaging Director
  • George PrestonDesign & Project Manager
  • Kelly BallingerHead of Partnerships
  • Jim AndertonProduction Manager
  • TheodoreEmployee Welfare
Meet the team