Case Studies

Case Study

AI Chip Housing

The project scope was to create a vibrant multicoloured peripheral for servers that stood out from the standard black generic unit.

Our customer said:

“Graphcore’s Intelligence Processing Unit (IPU) represents a significant shift in the chip industry for AI and other applications. To reinforce this difference, our casework was designed in bright colours with multiple elements to make a real statement. FRP were recommended to us as the right partner to develop and deliver the precision manufacturing combination of plastic injection moulded tiles (minimal draft, tight tolerances) and metal casework. FRP’s Full Service Rapid Manufacturing (FSRM) process meant that we could launch our product from a single set of tooling, saving us time and money. Our investors and customers are delighted with the result, as are we”.

JW, Hardware Engineering Director - Graphcore

Case Study

Flip Top Cap

The project scope was to produce a flip top cap for a packaging company. Our solution had to be fully representative of a working production part.

Our customer said:

“We had a need to provide our client with a prototype part that represented a full production quality moulding. FRP provided us with a number of solutions including vacuum casting, which was the chosen route. This enabled us to supply our client with a functioning, production quality prototype lid in the short timescale we required. We found FRP’s approach to the project fast, helpful and flexible, helping us meet our client’s requirements”.

Ian Bennett, Commercial Director - Bell Packaging

Case Study

Project L550 - New Discovery Sport

The project scope was to produce a variety of interior and exterior trim and under-bonnet parts using a variety of processes and materials; up to 100 car sets, all in under 4 weeks.

Our customer said:

“FRP’s fantastic service was instrumental in enabling us to test and develop a range of components for our new Discovery Sport vehicle. FRP helped us with a range of parts covering many critical vehicle attributes; our need for fast, real parts is always significant, and FRP rose to the challenge in every department. They are one of a select band of prototype and low volume suppliers that deal in a wide range of materials and processes - we find this particularly helpful when we need quick responses to the challenges of developing a new vehicle from scratch.”

Paul Cleaver, L550 Vehicle Programme Director - Jaguar Land Rover

Case Study

Pump Cover

The project scope was to manufacture a transparent cover to be able to see the internal working of the pump during assembly.

Our customer said:

“We had an urgent need to see what was going on inside one of our products. The production moulded cover was opaque, so this meant sourcing a batch of accurate replicas in a crystal clear material. We contacted Joe at FRP who advised us of a few different possible solutions and the comparative cost/benefits of each one. He suggested we went with a CNC machined clear PMMA part - this proved to be the best value method to give the results we required. On receiving the 1st off part ahead of time I have to say we were very impressed - the quality and finish was fully representative of a production moulded component and we have since ordered further parts for the same function. Great service from a knowledgeable team.”

Dave Willis, Project Buyer - Watson-Marlow Ltd

Case Study

Fire Pump

The project scope was to produce a fully accurate scale model of an offshore fire pump for Ellehammer's show stand at a trade fair.

Our customer said:

“At Ellehammer we design and develop emergency fire pumps for offshore use around the world. In order to showcase our latest product at an important trade fair we needed an accurate scale model in a standard red colour for offshore fire pumps. FRP managed and supplied the whole project for us in only 3 weeks, from up front CAD translation and managing the various manufacturing techniques required (including rapid prototyping and conventional model making) right through to personal delivery in a custom-made transport case. We are overjoyed with the result and very excited about showing it to our customers. Great service from a great company!”

Erik Hansen, Technical Manager - Ellehammer A/S

Case Study -

Technology Demonstrator Modules

The project scope was to produce 100 sets of 9 injection mouldings (inc. 52 x threaded brass inserts per set) tooled, moulded, inserted & delivered in 6 weeks

Our customer said:

“We needed a complex assembly of 9 injection mouldings (including 52 brass inserts per set) to make 3 product variants for our product launch at the Mobile World Congress Show. These were highly visible technology demonstrators and critical to our presence at the event. FRP delivered on time and to our exact specification, even incorporating some late changes that we needed for the last minute! Our CEO was delighted with the completed units and the event was a great success for us. We look forward to working with FRP on our products for next year and continuing to build the relationship.”

Head of Global Sourcing & Procurement - Telecoms Company

Case Study

Hull and Deck for New Yacht

The project scope was to manufacture a 1:1 scale, 28m long master pattern in 6 weeks, with gloss paint finishing & sign off in 4 weeks and full production GRP mould manufacture in 8 weeks.

Our customer said:

“Oyster Yachts is an international market leader of world-class cruising yachts. When it came to the hull and deck for the new 885 we chose FRP as our trusted partner for managing the master pattern ('plug') and mould manufacture on this critical new boat. The FRP team delivered sketch models, plug and moulds to our existing specifications by leveraging the latest proven rapid manufacturing technologies. In fact, the whole process worked so well that we chose to repeat it for the recent 825 project, which included the most complex deck moulding we had ever designed - incorporating all the deck furniture in the main moulding and hence saving us thousands of pounds downstream.”

Andrew Martin, New Product Development Manager - Oyster Yachts Ltd

Case Study

Kano Case

The project scope was to produce a high quality casework component with a gloss finish, to be used as a visual representation of a production component with a turnaround time of 5 days.

Our customer said:

“At MAP we like to offer our clients new ways of looking at - and solving - the problems they present us with. FRP play a crucial part in this process by providing us with the fast real parts we need to test and develop our ideas. For the recent Kano casework project, FRP advised us on what materials and finishes were available and supplied a range of parts from different processes, all of which fed into the kit we developed for our client. We look forward to working with FRP on other projects in the future.”

Jon Marshall, Studio Director - MAP

Fenland RP Ltd, Units 4 & 5, Evergreen Venture Park, Barton Road, Wisbech, Cambridgeshire, PE13 4TP.

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