Coventry-based HPL Prototypes, a leading manufacturer of bespoke automotive parts for brands like Bentley and McLaren, has transformed its production capabilities by bringing additive manufacturing in-house. The company invested in a Stratasys NEO800 stereolithography system through Tri-Tech 3D, eliminating costly outsourcing delays while improving part quality and turnaround times.
The High Cost of Outsourcing
Previously, HPL relied on external bureaus for 3D-printed components requiring specialized materials like ultra-clear resins—a process that proved expensive and unpredictable. Finance Director Glyn Horsfield noted that outsourcing often led to monthly costs in the tens of thousands, alongside scheduling uncertainties. “Delays in shipping or bureau workloads meant we couldn’t guarantee rapid turnarounds, hurting customer satisfaction,” he explained.
A Game-Changing Investment
The NEO800’s 800 x 800 x 600 mm build volume allows HPL to produce large, seamless parts—such as headlight bezels and seat backs—in single prints. Its open-resin compatibility also enables material flexibility, including the Somos WaterShed XC 11122 resin, which delivers ABS-like durability with optical clarity. According to Horsfield, the system paid for itself within months, achieving positive cash flow in its first month of operation.
Expanding Capabilities and Clientele
Beyond supplementing CNC machining for automotive gears and housings, the NEO800 has unlocked new markets. HPL now supplies Cranfield Aerospace Solutions with hydrogen-electric aircraft components and supports its Allesley coachbuilding division in crafting ultra-exclusive cars. “Clients can now see their bespoke vehicles being printed on-site,” said Sales Manager Tom Spicer.
A Blueprint for Manufacturing Agility
With Tri-Tech 3D’s responsive support and the NEO800’s intuitive operation, HPL has slashed lead times while gaining full control over margins. “This isn’t just about cost savings—it’s about redefining what’s possible in luxury automotive prototyping,” Horsfield concluded. The move underscores how in-house AM can drive competitiveness in high-stakes manufacturing sectors.
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