Resources

THE CHALLENGE:
Our client required 250 prototype bumper assemblies for the first phase of Vehicle Build (VB) trials on the Range Rover Sport programme.

OUR APPROACH:
Pro2Pro combined 3DP, PU Casting, CNC machining, and Injection Moulding. Mild steel tooling with loose cores reduced lead times while ensuring high repeatability. Once produced, parts were painted, welded, assembled, and packaged for delivery.

THE RESULTS:

• Delivered 30 full assemblies within 10 weeks.

• Supplied production-representative bumpers.

• Provided boxed assemblies ready for VB build.

THE IMPACT:

JLR validated both the design and chosen materials early, reducing risk before committing to production tooling.

WHY Pro2Pro:
We combined rapid tooling, finishing, and assembly to supply complete, production-ready assemblies under tight deadlines.

THE CHALLENGE:

A customer required a unique trophy for a swimming event in Las Vegas.

OUR APPROACH:
Using the Stratasys J750, Pro2Pro created test samples then printed the complete trophy in one run. A machined, anodised aluminium base was added for durability and premium finish.

THE RESULTS:
Delivered a one-of-a-kind trophy with a translucent effect.

• Produced the entire top section in one seamless print.

• Supplied with bespoke aluminium base.

THE IMPACT:
The client received a stunning award with cutting-edge design and finish.

WHY Pro2Pro:
By combining multi-material 3D printing with precision machining, Pro2Pr delivered a high-quality, bespoke solution.

THE CHALLENGE:
As part of a new model programme, Jaguar Land Rover (JLR) required almost complete prototype interiors along with front and rear bumper systems. The parts had to be both visually accurate and dimensionally correct, enabling their engineering teams to carry out early build evaluations (VB Builds) and downstream equipment development. With only 10 weeks from order to delivery, speed and precision were critical.

OUR APPROACH:
To meet the demanding brief, Pro2Pro deployed a dual-process strategy:

• Interior Components – Manufactured using mild steel tooling with loose cores.
• Exterior Bumpers – Delivered using PU casting from silicone tooling.

THE RESULTS:
Within 10 weeks, we supplied JLR with a comprehensive suite of parts covering both interior and exterior systems. These parts were used for VB builds, fit and function trials, tooling development, and stakeholder demonstrations.

THE IMPACT:
We helped JLR accelerate its development cycle, reduce downstream risk, and validate assembly equipment before production tooling was committed.

WHY Pro2Pro:
Our strength lies in blending multiple rapid manufacturing methods into a single solution.

THE CHALLENGE:
A customer needed prototype suitcases for trade shows.

OUR APPROACH:
Pro2Pro used 3D printing, silicone tooling, PU moulding, and onsite spray finishing to create show-standard prototypes.

THE RESULTS:

• Delivered trade-show ready prototypes.

• Enabled evaluation of material choices.

• Identified costly changes early.

THE IMPACT:

Prototypes supported trade show success and market feedback gathering.

WHY Pro2Pro:
We take CAD models to production-quality prototypes quickly, enabling confident design validation.

THE CHALLENGE:
A customer required a bonding fixture to simulate the production assembly process for a vehicle tailgate.

OUR APPROACH:
Pro2Pro fabricated and CNC machined the fixture, incorporating overmould rubber casting and heating elements to replicate bonding conditions.

THE RESULTS:

• Delivered a production-representative bonding fixture.
• Enabled testing of bonding methods with real off-tool parts.
• Provided accurate feedback on design and fitment.

THE IMPACT:

Customer gained confidence in their bonding strategy well before ramp-up.

WHY Pro2Pro:
We combine multiple processes to replicate production conditions and deliver accurate fixtures.

THE CHALLENGE:

A customer required accurate measurement of flexible automotive side sills.

OUR APPROACH:
Pro2Pro CNC machined model board on aluminium, with clamps and gauges to hold sills in CAD-defined orientation, enabling accurate CMM and 3D scans.

THE RESULTS:
Delivered a precision fixture for repeatable measurements.

• Enabled accurate dimensional reporting.
• Supported validation and quality assurance.

THE IMPACT:
Customer gained confidence in their production process through accurate inspection data.

WHY Pro2Pro:
We design and manufacture bespoke fixtures in-house, ensuring even flexible components can be validated effectively.

THE CHALLENGE:
A client needed a scale model of a building development for planning submission.

OUR APPROACH:
Pro2Pro used the Stratasys J750 to 3D print the entire model in one build, eliminating hand assembly and reducing cost/time.

THE RESULTS:

• Delivered scale model in one week.
• Provided accurate, visually impressive representation.
• Saved cost compared to traditional model making.

THE IMPACT:
The model supported a successful planning submission and professional presentation.

WHY Pro2Pro:
We use advanced 3D printing to replace traditional model-making with faster, more cost-effective solutions.

THE CHALLENGE:
A car manufacturer required 40 bespoke engine covers for low-volume production, functional under high-temperature conditions.

OUR APPROACH:
Pro2Pro 3D printed a master for validation, then created a silicone RIM tool to cast high-temperature PU parts. Covers were painted and branded with logo.

THE RESULTS:

• Delivered 40 PU engine covers within 2-3 weeks.
• Validated fit/function before tooling.
• Supplied heat-resistant, production-ready covers.

THE IMPACT:
The customer launched quickly and cost-effectively, avoiding high tooling costs.

WHY Pro2Pro:
We align materials and processes to performance needs, delivering low-volume solutions fast.