Quantity R&D Metal Prototypes
From R&D to Production Readiness
At Regal Metal Products, we understand that successful product development requires high-quality prototypes at every stage. Whether you need a few parts for initial testing or a medium-quantity run to bridge the gap to full production, we provide functional, production-representative parts for testing and evaluation.
Why Prototype with Regal Metal Products?
- With over 50 years of metal stamping experience, we offer:
- Production-grade prototypes that accurately represent final parts
- Fast turnaround times to keep your development schedule on track
- Cost-effective solutions for both low and medium-volume needs
- Expert guidance from concept through testing
Limited Quantity Prototypes for Research & Development
Our limited quantity prototyping services provide manufacturers with the parts needed for initial design validation and testing.
Our Prototyping Capabilities
Materials Available:
- Carbon steels (various grades)
- Stainless steel alloys
- Aluminum (5000 & 6000 series)
- Specialty metals (available upon request)
Tolerance Standards:
- Standard: ±0.005″
- Tight tolerance capability: ±0.002″ when required
Production Methods:
- We use multiple approaches based on your needs:
- Modified production tooling for near-identical parts
- Bridge tooling for interim production
- CNC machining for complex geometries
- Hand fabrication for unique one-off pieces
Common R&D Prototype Applications
- Automotive Development: Structural component testing, fit and function validation, crash test components
- Agricultural Equipment: Durability testing parts, field trial components, ergonomics evaluation pieces
- Commercial Appliances: Design verification units, user interface testing, thermal performance evaluation
Medium Quantity Prototypes for Production
We specialize in medium-quantity prototype runs to give you the perfect balance between testing functionality and preparing for full manufacturing. These runs (typically from hundreds to a few thousand pieces) help you go beyond initial design checks by:
- Simulating production conditions to spot potential issues before final tooling investment.
- Testing assembly fit and function in larger systems.
- Validating material choices over multiple cycles.
- Supporting pilot production for field testing and market trials.
How We Make Medium-Quantity Prototypes Work for You
We take a practical approach so that your parts are ready for production:
- Using Production-Ready Methods
- Stamping with similar press conditions as future production runs.
- Using tooling techniques that align with final manufacturing processes.
- Keeping tolerances tight to meet full-production standards.
- Flexible Tooling Solutions
- Existing tooling: We can run your current dies or fixtures to your specs.
- Modified or temporary tooling: A cost-effective way to test parts before final tooling is complete.
- Multi-stage progressive dies: For efficiently handling more complex parts in medium runs.
- Supporting Secondary Operations
Prototypes often need more than just stamping. Our in-house capabilities include:
- Welding: Spot welding, MIG and other methods.
- Bolt-staking: For secure fastening without additional hardware.
- Assembly: Putting together multi-part components for functional testing.
Industries We Serve
Our medium-quantity prototypes support many applications, including Automotive brackets and mounts, Heavy Truck reinforced parts, Agricultural wear-resistant components and Appliance housings and hardware.
The Regal Metal Prototyping Process
Design Review
Our engineers evaluate your CAD files or sketches, identify potential manufacturing considerations and provide design-for-manufacturability feedback.
Manufacturing Plan
We determine the optimal production method, select appropriate materials and establish quality checkpoints.
Prototype Fabrication
Your parts are built using dedicated production time slots, with careful monitoring of key dimensions and documentation of process parameters.
Delivery & Feedback
We provide careful packaging, complete documentation and post-delivery support.
Why Choose Regal for Your Prototyping Needs?
- Production Knowledge: Our prototypes are created with full production realities in mind, helping you avoid costly redesigns later.
- Flexible Approaches: We adapt our methods to your specific needs, whether you require a few hand-fabricated samples, a small batch of production-like parts or multiple design iterations for testing.
- Secondary Services: Many prototypes require additional processing, and we offer welding and assembly, surface finishing, functional testing and material certification.
Getting Started with Your Prototype Project
To begin your project:
- Share your design files, prints or sketches.
- Specify needed quantities and timeline.
- Discuss any special testing requirements.
You will receive an all-inclusive quote within 7 business days.
Our team will help you bridge the gap between your design concepts and production-ready parts. With our prototyping services, you can validate designs, test materials and evaluate performance before making significant production investments.
Interested in working with Regal Metal Products?
Contact us today to discuss how we can support your product development needs
with high-quality, limited quantity prototypes.