3D Printing Service for Alton
Rapid Prototyping and Custom 3D Printing Solutions
🛠️ Case Study:
Alton – Rescuing a Heritage Mill’s Broken Gear Cover with 3D Printing
Location: Alton, Hampshire
Client: Owner of a historic watermill conversion
Service Provided: Reverse Engineering, CAD Design, Engineering‑Grade PETG Printing
Delivery: Royal Mail Tracked 24®
Turnaround: ~48 hours
🌊 Context: Historic Mill, Modern Problem
Alton is a market town, surrounded by rural estates and classic watercourses. One of our clients owns a restored watermill in the countryside near Alton. The mill is now partly a workshop and partly a heritage site open to visitors. The drive chain and gear train are still operational, but one of the plastic gear box covers cracked and deformed over time.
That cover wasn’t just cosmetic—it sealed the internals from moisture, debris, and small stones. Without it, grit would get in, the chain would wear faster, and the mill’s mechanical bits would seize sooner. The trouble: the original manufacturer no longer existed, no drawings were kept, and the part had been hand‑modified over decades.
They reached out to us, asking: could we recreate this cover in a tougher modern plastic? They needed it ahead of the tourist season’s opening day.
🧠 Reverse Engineering: From Broken Split to 3D CAD
The client sent us the broken cover (via Royal Mail Tracked 24®) and a few photos of the gearbox internals. The cover had warped around screw bosses and cracked along a stress line. Our first task was cleaning up the part, scanning both intact and damaged sections.
In CAD:
We reconstructed missing geometry from symmetry and photo references.
We incorporated reinforcement ribs to reduce deformation.
We added drainage holes disguised in design so water won’t pool.
We made screw bosses slightly thicker to resist over-tightening.
We then shared a rendered model with the client, highlighting the changes we’d introduced to improve durability.
⚙️ Material Choice & Print Strategy
Given the outdoors, moisture exposure, occasional splashes, and occasional UV from indirect sunlight, PLA was out. ABS wouldn’t reliably last. We chose PETG for its balance of toughness, water resistance, and UV stability.
We printed at 100% infill, solid, no internal hollows, to resist warping and mechanical stress. The layer height was tuned to give enough surface resolution without brittleness.
After printing, we post‑processed:
Light sanding on the sealing lip
Application of a thin UV‑cured resin coat for smooth sealing surface
Pressure test with mild water spray inhouse
📦 Delivery & Outcome
We shipped the final part via Royal Mail Tracked 24®, arriving in Alton the next morning. The client installed it the same day. It snapped in place, sealed perfectly, and they reported no rattles or misalignment.
They later sent feedback: the new cover looked better than the original, felt more robust, and had zero distortion after a week in damp weather.
They also asked us to digitise two more parts for the mill as spares.
🏘️ Why This Works for Alton
In towns like Alton, you deal with older buildings, heritage installations, bespoke restorations. Off‑the-shelf parts often aren’t an option. Getting something made abroad takes time and cost. What you need is someone who can take what you’ve got and make something better.
We’re that link: local engineering, national reach. We don’t just replace—we improve.
1. What are the key properties of ABS filament?
ABS (Acrylonitrile Butadiene Styrene) is renowned for its strength and durability. It melts at approximately 220–250°C and requires a print bed temperature of 80–110°C to ensure proper adhesion. With a tensile strength of around 40–50 MPa, ABS is ideal for parts subjected to mechanical stress.
2. How does PLA filament perform in 3D printing?
PLA (Polylactic Acid) is favored for its ease of use and biodegradability. It has a melting temperature between 180–220°C and a recommended bed temperature of 50–60°C.
PLA offers a tensile strength of 50–60 MPa, making it suitable for prototypes and decorative items
3. What distinguishes PETG from other filaments?
PETG (Polyethylene Terephthalate Glycol) combines the ease of PLA with the strength of ABS. It melts at 220–250°C and adheres well to beds heated to 70–90°C.
PETG is known for its impact resistance and clarity, making it suitable for functional parts and containers.
4. Why choose Nylon filament for 3D printing?
Nylon is celebrated for its flexibility and toughness. It requires a melting temperature of 240–260°C and a bed temperature of 60–80°C.
With a tensile strength of 50–70 MPa, Nylon is ideal for mechanical parts and tools.
5. What are the benefits of Nylon infused with Carbon Fiber?
Nylon + Carbon Fiber offers enhanced rigidity and strength. It melts at 240–260°C and benefits from a bed temperature of 60–80°C.
This composite boasts a tensile strength of 80–100 MPa and a flexural strength of 120–150 MPa, making it perfect for high-stress applications
6. How does TPU filament stand out?
TPU (Thermoplastic Polyurethane) is known for its flexibility and elasticity. It melts at 220–240°C and adheres well to beds heated to 50–60°C.
With a tensile strength of 20–25 MPa,
TPU is ideal for parts requiring flexibility, like gaskets and wearable items.
7. What are the characteristics of Polycarbonate filament?
Polycarbonate (PC) is prized for its strength and heat resistance. It melts at 250–300°C and requires a bed temperature of 80–110°C.
PC is suitable for high-impact applications and parts exposed to elevated temperatures
8. Why use Castable Resin in 3D printing?
Castable Resin is designed for high-detail casting applications. It transitions to gas at high temperatures, leaving minimal ash residue.
With a tensile strength of 32 MPa, it's ideal for jewelry and dental molds.
Testimonials
" Very helpful guys, patient too. Had a cool design to print a custom backplate for my Legion Go handheld device, and these guys stepped up and delivered!
Great communication and prompt delivery once the print was successful.
Of course the backplate fits perfectly, even clicks into place. Printed using PETG CF at a very competitive price.
I Highly recommend them! "
" I needed some very small plastic shelf support brackets, that were no longer provided by the manufacturer of my old SieMatic kitchen units.
Mitchell and Son Design were approached and produced a 3D model and then 3D printed the brackets very quickly, and to an excellent standard.
I highly recommend their service and expertise. "
" Posting on behalf of my father. He had four dust caps made for some Girling brake cylinders for a 1950s Riley 2.5ltr. They were perfect, spot on. Definitely recommended."
" A very nicely made part and these guys are easy to deal with, planning the next job right now."
Where to start and how?
Experience the convenience of our 'Instant Online Quote' system for your 3D printing and modeling needs. Whether you're located in the United Kingdom, the United States, or Europe, Mitchell and Son's 3D Printing Services is your ideal choice. With a variety of materials to choose from, our system swiftly provides you with an estimate, saving you time and hassle.
Say goodbye to the complexities of finding the right 3D printing solution and focus on your project. Contact us today, and enjoy excellent customer service during our business hours from 8 am to 5 pm, Monday to Saturday. Explore unique materials like Resin, Metal, Full Color, and various plastics for your 3D printing projects.
Dwight Anton Mitchell
Sales and Operations Director
Dwight is our Sales and Operations Director, he brings a wealth of expertise to our team. With two decades of corporate sector experience in production support roles and a background as a trained motor mechanic, he has a proven track record of excellence. His career has included positions at renowned companies such as Eaton Aero Space, Wartsila, and Vertu.
Within our organization, Dwight has played a pivotal role in driving our most dynamic and impactful campaigns. His contributions have consistently led to revenue growth, acquisition of new clients, and the establishment of our clients as industry leaders.
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3D Printing Service for Alton
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