Workshop Capabilities Summary

Bayly have extensive workshop capabilities including rapid prototyping, master models for use in rapid prototyping and development models to test functionality, form and to aid in the development and specification of products.  Our capabilities also include, presentation models, making moulds and patterns to produce parts by thermoforming, injection moulding and casting and supplying jigs, gauges and fixtures to clients to suit requirements up to full turn-key design, manufacture and validation.  Bayly maintains state of the art workshop equipment and ensures the most stringent quality and safety standards are maintained.

>Rapid Prototyping - Bayly uses master models to produce silicone rubber tooling in order to produce vacuum cast parts for client’s needs.  Bayly’s automated vacuum casting equipment is able to produce part weights to 850 grams and part dimensions of up to 500 x 500 x 400 mm.  Larger parts up to 20kg in weight and up to 1.5 metres long can also be produced using a slightly modified process.  Bayly’s equipment incorporates a heated crucible that allows for the casting of low melt temperature metal alloys and investment waxes.

Bayly stocks a wide range of materials including epoxies, urethanes and polyesters that can be used to simulate the properties of almost any plastic material.  By adding reinforcements and fillers, Bayly can tune the performance of the materials to provide the best possible solution.
 
>Master Models - Bayly uses it’s NC milling equipment to produce master models for use in the rapid prototyping process.  Using high speed 4 axis machining, Bayly are able to produce most parts as required.  Our NC milling capacity is currently rated to 650 x 500 x 250 mm.  Our network of suppliers are able to extend our capability in this area without limitation.  Where necessary, Bayly use other SLA and SLS master model making processes to produce parts where these processes provide the best value solution.

>Development Models - Bayly’s workshop produces development models to test functionality, form and to aid in the development and specification of products on a daily basis in support of the design and manufacturing projects.  As a key part of our process, these same types of block models, functional models and works like models are available to our clients as stand alone items.  These models are typified by their semi-finished nature and are designed to help visualise, communicate and test the ideas of designers, engineers, marketeers, inventors, entrepreneurs and manufacturers.  Their purpose is to provide the best possible value during the early stages of the development journey.

>Presentation Models - Bayly’s presentation models are manufactured by our master craftsmen to exacting standards.  Our experience with painted and appliqué finishes ensures that the final model provides an excellent facsimile of a production product. 

>Patterns and Moulds - Bayly uses it’s NC machining capacity to produce moulds in suitable tooling materials for manufacture of rubber prototypes and can produce parts using room temperature vulcanising materials or heat temperature vulcanising materials as required.  Bayly’s compression moulding equipment allows us to produce prototype parts from the actual elastomeric materials that would be used in production.

Thermoforming patterns are used to produce parts for new packaging products, plates, trays, equipment casings, fascias and a wide variety of trim parts used in medical, hospital, aerospace, FMCG, defence and automotive industries.  The thermoforming process allows prototype parts to be produced in the actual plastic materials that would be used in production.

Injection moulding tools are able to be manufactured using traditional or soft tooling techniques.  Bayly uses soft tooling techniques to produce moulded parts where the specific critical material performance cannot be achieved by simulant cast materials.  In these cases, the options include tooling made from cast metal filled epoxies, NC machined tooling boards, NC machined aluminium tool inserts.  Bayly have a range of tooling bolsters that can then be fitted with the tooling inserts / moulds and have these in turn fitted to injection moulding equipment to produce parts in quantities of hundreds of parts (dependent on the material and processing conditions).  This approach reduces the lead time and cost associated with prototyping parts using injection moulding processes in the actual material they are designed to be made from.

>Jigs and Fixtures - Bayly provides a service that supplies jigs, gauges and fixtures to clients to suit requirements up to full turnkey design, manufacture and validation.  Jigs and fixtures are required for part inspection, part testing and to aid in non-automated assembly process across all industries including pharmaceutical, defence, automotive, medical and construction fields.

>Workshop Equipment - Bayly maintains state of the art workshop equipment for the following processes; 4 axis NC milling, Manual milling, Manual lathe turning, TIG welding, MIG welding, Vacuum casting, Compression Moulding, Component pressing, Metal cutting and fabrication, Spray painting, Non-metal cutting, shaping and fabrication, Inspection and measurement, Testing, data acquisition and evaluation.

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