This website is not optimized for Internet Explorer! Please consider using a different modern browser such as Chrome, Edge or Firefox.

  • Capabilities
    • 3D Printing

      Turn your design files into affordable functional prototypes and end-use parts.
      • SLA
      • FDM
    • CNC Machining

      Precision parts via modern machining techniques and technologies.
      • CNC Milling
      • CNC Turning
    • Casting

      A versatile process for prototype or production parts of all shapes, sizes and color.
      • Urethane & Silicone Casting
    • Laser Cutting & Engraving

      Cut and engrave with consistent quality and precision.
      • Laser Cutting
      • Laser Engraving
    • Finishing

      Dramatically increase the life and look of your part.
      • Painting & Color Matching
      • Pad Printing
      • Surface Treatments
  • Services
    • Rapid Prototyping

      An extensive range of rapid prototyping technologies to meet your project goals.
    • Low Volume / Short-Run Production

      For customers who need high quality products in limited quantities.
    • Visual Models

      High-quality appearance models of your final design.
  • Company
  • Portfolio
  • Contact us

Our work speaks for itself

Our Portfolio

  • Concept Bike

  • Gas
    Mask

  • Raven Mouse

  • Coffee Maker

  • Body Scanner

  • Vector Elite

  • Dust Collector

  • Sound Wave

  • Pacemaker

  • Tea Pot

  • Leaf Blower

  • Splatter Guard

  • Slow Cooker

  • Medical Model

  • Bionic Ankle

  • Two-Slot Toaster

  • Bicycle Fork

  • Axe Backpack

Project

Cypher Bike

Quantity

1

Processes

CAD, SLA, CNC & Finishing

Overview

Initial CAD data was received from an individual within the design industry. The CAD was edited for prototype purposes and built using SLA & CNC processes. The model was finished using custom finishing processes, specifically soft touch coatings to make characteristically appealing surfaces. The Cypher Bike model was used to communicate a concept bike design.

Project

PRISM Helmet

Quantity

25

Processes

CAD, CNC, SLA, Cast Urethane & Cast Silicone

Overview

Each helmet assembly consisted of 4 cast silicone parts, 10 cast urethane parts, 18 machined aluminum parts, 2 textile pieces, and 1 optically clear vacuum-formed lens. A total of 25 assemblies were produced.

Project

Gaming Mouse

Quantity

3

Processes

CAD, CNC, SLA, Casting, Laser Cutting, Graphics & Finishing

Overview

The gaming mouse design was recreated to showcase our in-house capabilities. Each department within our company contributed to the final product. Model makers were given the freedom to use their choice of presentation style finishing techniques.

Project

Calphalon Coffee Maker

Quantity

1

Processes

CAD, CNC, Laser Etching, Graphics & Finishing

Overview

This prototype was produced using CNC machined parts from aluminum, ABS and acrylic. The simulated digital display was laser etched and backlit. Two carafes, a simulated glass and a thermal, were also created. This model was professionally photographed by the client for use in packaging and the web.

Project

Vectra WB360

Quantity

3

Processes

CAD, CNC, SLA, Laser

Overview

The majority of this model was created using SLA components with CNC machined and laser cut details. The final finish request was to best replicate production finishes with attention to custom color, gloss and texture. PSG produced three 1:10 scale models to be used as sales samples. The award winning design of this system was created by HS Design for Canfield Scientific. This imaging system is used specifically for dermatology at many top cancer institutions worldwide, capturing nearly the entire skin surface in macro quality resolution with a single capture to monitor and map pigmented lesions and distributed diseases.

Project

Vector APTA

Quantity

20

Processes

CAD, SLA, Urethane Casting, Laser, Finishing

Overview

This enclosure was produced for Bioness, Inc. for product demonstration purposes for their Vector Gait and Safety System. The enclosure was made up of 20 cast urethane parts, all of which were painted using 3 different Pantone colors. Satin and semi-gloss top coats were used to achieve a presentation finish. The company logo is displayed with a clear SLA part tinted orange and the product name was produced from laser cutting.

Project

Donaldson Torit DFE6

Quantity

1

Processes

CAD, SLA, CNC, Graphics & Finishing

Overview

PSG provided CAD services to manipulate the supplied production data to create a high end visual model of this dust collector system. SLA and CNC components were used to assemble this model. Color matching to custom swatches, rub down graphics, and standard spray finishing techniques were applied to showcase the level of detail. This 1:8 scale model was displayed in the Donaldson Company Welcome Center to showcase existing product offerings.

Project

Soundwave

Quantity

1

Processes

CAD, CNC Turning

Overview

A CNC lathe was used to build multiple sections designed to screw together to artistically represent the chorus of a song in soundwave form.

Project

Pacemaker Model

Quantity

1

Processes

CAD, CNC, Finishing

Overview

This over-sized scale model was developed from a production pacemaker to be used at trade shows for demonstration purposes. The model was constructed from a combination of CNC machined acrylic and ABS components as well as aluminum tubing. Custom finishing techniques were applied to meet client specifications.

Project

Calphalon Teapot

Quantity

1

Processes

CAD, CNC, Finishing

Overview

This model was CNC machined from aluminum and ABS. Radially brushed and topcoated, the aluminum was finished to match the appearance of production stainless steel. The lever and whistle assembly were made to actuate.

Project

Leaf Blower

Quantity

1

Processes

CAD, SLA, Low Durometer Urethane, Finishing

Overview

This full scale model was constructed primarly from SLA components. The handle grips were cast in a low durometer urethane to achieve a tactile feel as well as simulate a two shot overmolded component.

Project

Calphalon Splatter Guard

Quantity

1

Processes

CAD, CNC, Low Durometer Casting, Finishing

Overview

The handle of this prototype was CNC machined from stainless steel and overmolded with a low durometer grip. The splatter guard itself was created from CNC machined aluminum that was radially brushed and top coated with a tinted clear coat to simulate stainless steel.

Project

Calphalon Slow Cooker

Quantity

1

Processes

CAD, CNC, SLA, Graphics & Finishing

Overview

This model consisted of CNC machined materials including aluminum, renshape, ABS, and acrylic. For realism, it was fitted with actuating buttons and a backlit display. This prototype was used in consumer evaluation as well as professionally photographed by the client for use in packaging and on the web.

Project

St. Jude Cardiac Lead

Quantity

1

Processes

CAD, CNC, SLA, Graphics & Finishing

Overview

This visual model depicts a cardiac lead that would connect a pacemaker to the heart muscle. The intricate structure of the wires was achieved using SLA components, while the remainder of the components were CNC machined. At 10 inches in diameter, this over-sized display model (approximately 110%) is used as a sales tool at trade shows.

Project

Prosthetic Ankle Joint

Quantity

50

Processes

CNC Milling

Overview

This part was designed to function within a prosthetic ankle. We machined numerous revisions in a multitude of metals including Aluminum 7075 and Titanium. This part showcases our 5th axis machining capabilities.

Project

Calphalon Two-Slot Toaster

Quantity

1

Processes

CAD, CNC, Graphics & Finishing

Overview

This prototype was CNC machined from aluminum, ABS and acrylic. Earlier versions were used in focus groups to help determine any necessary design changes, while this final version was professionally photographed by the client for use on the web.

Project

Bicycle Fork

Quantity

1

Processes

CAD, SLA, Finishing

Overview

This prototype was built using SLA technologies and given a presentation finish and top coat. Incorporating design features new to the bicycle industry, it was used for discussions related to upcoming Model Year Product Development. The model was taken to Europe for use as a point of focus to build excitement for new products that Manitou is bringing to the market.

Project

Axe Bottle Backpack

Quantity

1

Processes

CAD, CNC, Finishing

Overview

This prototype was modeled using dimensions based on the consumer product. After being scaled to size, the model was CNC machined from solid pieces of ABS plastic and assembled to create a watertight seal. Functioning as a tank for a water gun, the backpack was used as a prop for a TV bit on the Jimmy Kimmel Live Show.

Have a question in mind?

Let's start a conversation

Contact us

Capabilities

3D PrintingCNC MachiningMolding & CastingFinishingLaser Cutting & Engraving

Services

Visual ModelsLow-volume & short-run productionRapid Prototyping

Company

PortfolioAbout PSGCareersContact UsFAQ
Prototype Solutions Group, Inc.
1621 Indianhead Drive, Menomonie, WI 54751
Tel: +1 715.235.0156
Fax: +1 715.235.0160