Precision Manufacturing · Small Batch Specialists
Professional 3D printing and PU foam moulded parts — from single prototypes to small production runs. Fast turnaround, engineering-grade materials, no minimum orders.
What We Do
Two complementary manufacturing methods. One supplier. Simplified logistics for your project.
From rapid prototypes to functional end-use parts. We operate FDM, SLA, and SLS printers to match your material and tolerance requirements — with no minimum order quantity.
Polyurethane foam cast parts for cushioning, gaskets, props, ergonomic grips, packaging inserts, and custom shapes. Small batch production using silicone or 3D-printed moulds.
Design for Manufacturability review included with every order. We analyse your files and flag potential issues before production begins, saving costly reprints.
Sanding, priming, painting, vapour smoothing, and dimensional inspection. Every part ships with a quality report including measured critical dimensions.
How It Works
A streamlined five-step process designed to get your parts in hand as fast as possible.
Submit STL, STEP, or OBJ files via our quote form or email.
Receive a detailed quote within 4 business hours.
We review your files and flag any issues before printing.
Parts produced in 24–72h depending on complexity.
Inspection, finishing, and secure packaging. Tracked delivery.
Materials
Engineering-grade materials for prototypes, functional parts, and small-batch production.
| Material | Process | Key Properties | Tag |
|---|---|---|---|
| PLA+ | FDM | Easy, rigid, good detail | Popular |
| PETG | FDM | Tough, chemical resistant | Strong |
| ABS | FDM | Impact resistant, machineable | |
| TPU 95A | FDM | Flexible, wear resistant | Flex |
| Nylon PA12 | SLS | High strength, no supports | Strong |
| Standard Resin | SLA | Ultra-fine detail, smooth | Popular |
| Tough Resin | SLA | ABS-like, impact resistant | |
| ASA | FDM | UV stable, outdoor use |
| System | Density | Key Properties | Tag |
|---|---|---|---|
| Flexible Foam | 20–80 kg/m³ | Soft, cushioning, open-cell | Flex |
| Semi-rigid Foam | 80–200 kg/m³ | Energy absorbing, trim parts | Popular |
| Rigid Foam | 200–600 kg/m³ | Structural, dense, machineable | Strong |
| Skinned Foam | Variable | Integral skin, soft-touch finish | Popular |
| Flame Retardant | 30–150 kg/m³ | UL94 rated, transport industry | |
| Shore A10 Gel | Low | Ultra-soft, medical-grade | Flex |
| High-Load Foam | 400–600 kg/m³ | Structural inserts, seating | Strong |
What We Offer
Every project is unique. Send us your files and specs — we'll come back with a detailed quote within 4 hours.
PROTOTYPING
Fast, accurate single parts for concept validation, fit checks, and design iteration.
SMALL BATCH
Repeatable parts for product launches, pilot runs, and short production cycles.
ONGOING SUPPLY
For clients needing consistent quality across recurring orders and supply agreements.
Why FormForged
We're not a faceless online bureau. We're a small team of engineers and makers who genuinely care about your project. We communicate quickly, flag problems early, and deliver parts you'd be proud to put your name on.
Standard 48–72h lead times on most FDM parts. Express 24h slots available on request. We hold stock materials for consistent quality and short lead times.
Order a single part or 500. Pricing scales fairly with volume — no arbitrary minimums that waste your budget.
Unique combination of 3D printing and PU foam moulding under one roof. Optimise each component for the right process without managing two suppliers.
Every project gets a DFM review. We'll tell you if a small geometry change will save you money or improve part strength before we press print.
FAQ
Get a Quote
Tell us about your project and we'll come back with a detailed quote within 4 business hours. No commitment required.