Consolite offers a very strong capability in rapid prototyping for its customers. A stereolithography facility provides the ability to generate three-dimensional models very quickly, direct from CAD files. Complex shapes that might take days or weeks to get machined as one-offs can be produced in a matter of hours at comparatively low cost. The process is ideal for production of design prototypes, such as for the rapid evaluation of new concepts or for visualising the fit of complex assemblies. It is perfect for the production of demonstration kit for exhibitions or sales presentations to customers. It can also be used to directly generate moulds, mould inserts and patterns for metal casting.

In addition we have our own well equipped machine shop, including a CNC machining centre, for use when more conventional metal products are needed quickly. This is often deployed to great effect in support of customer requirements for rapid response in NVG lighting modification programmes. It means that we can usually react with much greater speed and flexibility than larger competitors. A high power laser facility is also available for rapid, precise cutting of shapes or for engraving. Consolite can also provide a design service using its in-house CAD facility when required.

An excellent case study is provided by Consolite's new venture in forensic equipment. The complete system for revealing fingerprints on discharged cartridge cases has been designed and prototyped in-house. It includes a software controlled three-axis drive system, an automated powder dispensing system, an integrated camera and lighting system, and image processing software for the automated generation of enhanced fingerprint images from the entire circumference of the cartridge. The use of the stereolithography facility has greatly compressed the timescale to develop and test the mechanical prototype system, saving money and shortening time to market.