We attach great importance to customers' needs for product quality and rapid production.
We always insist that meeting customers' needs is to realize our value!
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+86 133 9281 9446
+86 133 9281 9446
Dec. 11, 2025
The client is an automotive interior manufacturer who required a full-size "center console" prototype for functional testing, assembly verification, and ergonomic evaluation. The part features large curved surfaces, deep grooves, and multiple mounting areas, making it difficult to produce accurately in a single process.
Our goal was to deliver a "high-precision, high-strength, and aesthetically pleasing" prototype that simulates the quality of the final product.
Customer Requirements
1.Full-size structural prototype for vehicle interior testing.
2.Smooth surface, meeting Class A standards.
3.High dimensional accuracy to ensure perfect fit with surrounding components.
4.Strength and stiffness meeting assembly testing requirements.
5.Rapid delivery for pre-production validation.
Main Challenges
1.Large overall dimensions – may lead to deformation during machining or forming.
2.Deep cavities and long cross-sections – require careful toolpath planning to avoid vibration and tool marks.
3.Multiple functional areas – (e.g., cup holders, control panel slots, armrest areas) require tight tolerances.
4.Complex geometry – difficult to control uniform wall thickness and structural stiffness.
We selected a hybrid prototyping strategy combining CNC machining + Vacuum casting, ensuring both precision and efficiency.
Step 1 — CNC Machining of Master Model
1.Machined the master model using ABS to secure dimensional stability.
2.Applied multi-axis toolpaths to achieve smooth transitions on curved surfaces.
3.Ensured all interface areas met ±0.01 mm tolerance.
Step 2 — Silicone Mold Fabrication
1.Built high-strength silicone molds based on the CNC master.
2.Reinforced molds for large-size casting to avoid deformation.
Step 3 — Vacuum Casting for Final Parts
1.Used PU material simulating PP/ABS performance.
2.Achieved smooth surfaces suitable for automotive interior appearance testing.
3.Produced multiple identical parts for cross-team review and assembly trials.
1.Manual sanding + primer + matte coating.
2.Final surface achieved near-production look and texture.
The final center console prototype met all structural and visual requirements.
1. Perfectly integrated with the main cockpit structure.
2. No warping or misalignment.
3. High-quality surface finish, closely matching mass-produced PP/ABS parts.
4. Successfully passed ergonomic and assembly tests.
The customer was very satisfied with the speed, accuracy, and appearance consistency of the product and has commissioned us to undertake several more automotive interior prototype projects.
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We attach great importance to customers' needs for product quality and rapid production.
We always insist that meeting customers' needs is to realize our value!
