Toxic Kimchi. Product Design

Category: How it’s done

  • Vacuum Casting – High-Quality Prototypes Without the High Volume

    Need production-quality plastic parts, but not quite ready for mass production? That’s where vacuum casting shines. It’s a smart, flexible way to make short runs of high-quality parts that look and feel like injection-moulded pieces — but without the cost and lead time of steel tooling.

    At Everlab, we don’t cast in-house, but we work with trusted vacuum casting partners to make sure you get great results, fast. We take care of the design, prep, and coordination — so you can focus on your product.

    What is vacuum casting?

    It starts with a high-resolution master model, usually 3D printed. A silicone mould is then made around that model. Once the mould cures, we can use it to cast up to 20–25 identical parts using polyurethane resins.

    The process happens under vacuum to remove air bubbles and get a smooth, detailed finish.

    Why choose vacuum casting?

    • Ideal for short runs – Perfect for 5 to 50 parts
    • Looks like the real thing – Great surface quality and detail
    • Fast turnaround – Usually ready within 1-2 weeks
    • Wide range of materials – From soft rubber-like to hard plastic-like resins
    • Flexible and affordable – No expensive steel moulds needed

    When to use it

    Vacuum casting is a great choice if you:

    • Need small series for testing, demos, or pilot runs
    • Want to show your product to investors or customers with a polished finish
    • Are bridging the gap between prototype and injection moulding
    • Need multiple copies of a part without investing in hard tooling

    How we help

    At Everlab, we design your part ready for casting and manage the entire process through our experienced partners. From choosing the right resin to checking the first parts, we’ll make sure everything matches your expectations.

  • CAD – Where Your Product Takes Shape

    CAD – Where Your Product Takes Shape

    Before anything gets built, it needs to be designed. That’s where CAD comes in.

    CAD (Computer-Aided Design) is the digital starting point of every product we make. It’s how we translate your idea into a detailed 3D model that shows exactly how your product will look, feel, and function — right down to the smallest screw or snap fit.

    We use professional CAD software to:

    • Create realistic 3D models of your product
    • Test how parts fit together
    • Spot problems early — before anything goes to production
    • Generate files for prototyping and manufacturing

    Why CAD matters

    Good CAD saves time, money, and frustration. It helps us make smart design choices early on, catch issues before they become expensive mistakes, and communicate clearly with manufacturers — whether we’re printing a one-off prototype or making thousands of parts.

    Whether you already have a rough sketch or just an idea in your head, we’ll turn it into a clean, accurate CAD model that forms the backbone of your product.

  • Milling – Shaping Your Product with Precision

    Milling – Shaping Your Product with Precision

    Milling is one of the most versatile and precise ways to shape solid materials into functional parts. Whether we’re working on a one-off prototype or a detailed part for production, milling allows us to cut, drill, and sculpt with a high level of control and precision.

    At our workshop, we’ve got both a manual mill and a CNC mill, so we can handle a wide range of jobs — from hands-on, quick adjustments to precise, repeatable cuts.

    What is milling?

    Milling involves using a spinning cutting tool to remove material from a solid block (usually metal or plastic). It’s ideal for flat surfaces, slots, pockets, holes, and complex shapes.

    We use milling to:

    • Make functional prototypes
    • Create enclosures, brackets, or fittings
    • Fine-tune parts with exact dimensions
    • Add features like holes, grooves, and surface finishes

    Manual vs CNC milling

    Manual milling – Great for quick, hands-on work, one-off parts, or simple changes. Our large manual mill lets us work with bigger pieces and make adjustments on the fly.

    CNC milling – Perfect for detailed, repeatable work. Our CNC mill is smaller but ideal for parts that require precision and consistency, especially in smaller batches.

    We often switch between the two, depending on the job — it’s all about what gets the best result for your product.

    Materials we mill

    We can mill a wide range of materials, including:

    • Aluminum – Light, easy to machine, and great for functional parts
    • Steel – Strong and durable for structural components
    • Stainless steel – Clean and corrosion-resistant, ideal for high-end or outdoor use
    • Plastics – Like POM, nylon, or acrylic for lightweight or test components
    • Brass – A nice balance of machinability and visual appeal

    From rough block to refined part

    Whether you need a single part or a short production run, milling helps us deliver strong, accurate, and great-looking components.

    Got a part that needs to be just right? Milling is probably the answer.

  • Quality Control – Because Good Enough Isn’t Good Enough

    Quality Control – Because Good Enough Isn’t Good Enough

    Whether it’s a single prototype or a full batch of parts, we believe in getting the details right. That’s why quality control is baked into every step of our process at Everlab.

    From visual checks to functional tests, we make sure your product looks sharp, fits together, and works as intended — before it leaves our workshop.

    Our quality control approach

    We don’t just tick boxes. We take the time to:

    • Inspect parts visually for scratches, defects, or surface finish issues
    • Measure dimensions to check tolerances and ensure proper fits
    • Test functionality if parts need to move, snap, or perform
    • Review assemblies to catch misalignments or weak connections

    Whether it’s CNC machined, 3D printed, welded, or painted, we check every part with care.

    Visual inspection

    Looks matter — especially for customer-facing parts or prototypes. We inspect:

    • Surface finish (scratches, dents, coating issues)
    • Clean edges and sharp features
    • Paint or coating consistency
    • Engraving clarity and alignment

    We’ll polish, clean, or rework parts if they don’t meet our visual standard.

    Testing and fit checks

    Some parts have a job to do — and we test that too. We:

    • Fit-test assemblies and moving parts
    • Verify screw threads, snap fits, or mechanical linkages
    • Perform simple stress or load tests when needed
    • Check that tolerances are within design specs

    When your prototype has a function to prove, we help make sure it does.

    Keeping you in the loop

    If something looks off, we don’t just fix it quietly. We’ll:

    • Let you know what we found
    • Suggest design tweaks (if needed)
    • Adjust or remake the part (if that’s the best solution)

    Great ideas deserve great execution. Our quality control helps your product live up to its potential — every time.

  • Assembly – Bringing It All Together

    A product isn’t just a collection of parts — it’s how those parts fit, move, and work together. That’s why we offer in-house assembly for prototypes and small-scale production runs.

    At Everlab, we make sure your design doesn’t just look good on paper, but works in the real world.

    Why assembly matters

    You can have the perfect 3D model, flawless machined parts, and a beautiful finish — but if something doesn’t fit right, align properly, or hold together, it won’t perform.

    Assembly helps us:

    • Catch and solve fit or tolerance issues
    • Verify that parts align, move, or snap together as intended
    • Build functional prototypes that feel like the final product
    • Create small production runs, ready to use or test

    What we assemble

    We regularly assemble:

    • Prototypes with multiple mechanical parts
    • Enclosures with electronics and connectors
    • Mechanical linkages or motion systems
    • Pre-production product runs
    • Test rigs and mock-ups

    We’ve put together everything from simple housings to functional test devices with multiple components and fasteners.

    How we support you

    Assembly at Everlab is tightly integrated with design. That means:

    • We design with real-world tolerances and fastening in mind
    • We test assemblies in stages to avoid late surprises
    • We suggest tweaks for simpler, more reliable builds
    • We document the process for future handover or scale-up

    If your product includes off-the-shelf parts (like hinges, motors, or PCBs), we can include those too — or recommend alternatives if needed.

  • Anodizing – Colour and Protection for Aluminium Parts

    Anodizing – Colour and Protection for Aluminium Parts

    If you’re working with aluminium and want a finish that’s durable, sleek, and professional, anodizing is the way to go.

    At Everlab, we often design aluminium parts with anodizing in mind. While we don’t anodize in-house, we work closely with trusted partners to get consistent, high-quality results — whether you’re after a bold colour, a subtle matte look, or long-lasting corrosion resistance.

    What is anodizing?

    Anodizing is an electrochemical process that turns the surface of aluminium into a tough, protective oxide layer. It’s not a coating — it’s a transformation of the material itself. That means it won’t peel or flake off.

    It can also be dyed in a range of colours, giving your parts a durable and aesthetic finish.

    Why choose anodizing?

    • Strong surface protection – Scratch- and corrosion-resistant
    • Sleek look – From deep black to vibrant colour or natural matte
    • No added thickness – Tolerances stay tight
    • Great for branding – Logos or details can be laser-engraved after
    • Long-lasting – Especially in outdoor or high-touch environments

    When to anodize

    Anodizing is ideal for:

    • CNC milled aluminium parts
    • Enclosures, frames, and housings
    • Buttons, knobs, and handles
    • Visual models that need a production-like finish
    • Parts exposed to wear, weather, or skin contact

    How we support it

    • We design with anodizing in mind, avoiding hidden pockets and sharp edges that can cause uneven results
    • We advise on colour and finish options (matte, satin, gloss)
    • We coordinate with anodizing partners to get consistent quality
    • We can combine anodizing with laser engraving for custom markings

    Want your aluminium parts to be tougher, better-looking, and built to last? Let’s anodize them.

  • DFM – Design for Manufacturing

    Great ideas don’t just need great design — they need to be manufacturable. That’s where DFM (Design for Manufacturing) comes in.

    At Everlab, we make sure your product isn’t just clever on paper — it’s ready for the real world. That means designing it so it can actually be made: efficiently, affordably, and at the quality you expect.

    What is DFM?

    DFM is the process of designing your product with the production method in mind from the start. That might sound obvious, but you’d be surprised how often it’s overlooked.

    By thinking about materials, tolerances, part geometry, and assembly early on, we avoid surprises (and costs) later.

    Why it matters

    Good DFM can:

    • Reduce production costs
    • Prevent delays and design changes later
    • Make tooling and manufacturing faster
    • Improve the quality and consistency of your product
    • Help scale your idea smoothly from prototype to production

    We do DFM across all the techniques we use — whether your product will be injection moulded, milled, 3D printed, or laser cut and bent from sheet metal.

    How we approach DFM

    • We adapt the design to the chosen manufacturing method
    • We simplify parts where possible, without losing function
    • We make sure everything fits together smoothly — even at scale
    • We collaborate with suppliers to match their capabilities
    • We balance design intent with production efficiency

    Whether you’re aiming for 50 pieces or 50,000, DFM makes sure your product is ready for it.

    Start early, save later

    The earlier we think about manufacturing, the easier (and cheaper) things get down the road. At Everlab, DFM isn’t an afterthought — it’s baked into our process.

    Let’s make it work — not just in theory, but on the factory floor too.

  • SLS Printing – Strong, Functional Prototypes

    Need a 3D print that can take a hit, handle stress, and still look sharp? SLS (Selective Laser Sintering) is your go-to. It’s one of our favourite methods for creating functional prototypes, test parts, and even low-volume production.

    We don’t run SLS printers in-house, but we work with reliable partners who deliver great quality and consistent results — fast.

    What is SLS printing?

    SLS printing uses a laser to fuse fine nylon powder together, layer by layer. The unused powder supports the part during printing, so no extra support structures are needed.

    The result? Tough, accurate, and complex parts, straight out of the printer.

    Why choose SLS?

    • High strength and durability
    • No support structures needed — great for complex designs
    • Good accuracy and fit
    • Ideal for functional testing
    • Can be dyed or coated for a cleaner look

    When we recommend it

    SLS is great for:

    • Prototypes that need to perform like real parts
    • Functional testing (snap fits, hinges, enclosures)
    • Short-run production
    • Mechanical components
    • Parts with complex internal geometry

    Typical materials

    Most SLS prints are made from nylon (PA12) or its variants. It’s strong, slightly flexible, and can handle real-world testing.

    We’ll help you pick the right material based on performance, stiffness, finish, and colour options.

    How Everlab helps

    We guide your part’s design for SLS to avoid warping, keep tolerances tight, and ensure good printability. We can also:

    • Recommend suitable finishes or coatings
    • Add labels, logos, or features into the print
    • Combine SLS prints with CNC, painting, or assembly
  • FDM Printing – Fast, Functional, In-House

    FDM Printing – Fast, Functional, In-House

    When you need a quick prototype or a handful of parts to test an idea, FDM 3D printing is one of the fastest and most flexible options — and we do it right here at Everlab.

    It’s our go-to for iterating early, mocking up forms, or producing small batches of functional parts.

    What is FDM printing?

    FDM (Fused Deposition Modeling) works by melting and extruding plastic filament through a heated nozzle, layer by layer. It’s the most accessible form of 3D printing — and incredibly versatile.

    Why we love it

    • Fast turnaround — we print in-house
    • Low-cost prototyping
    • Good mechanical properties
    • Wide range of materials
    • Perfect for fit checks and form testing

    We can print and test a part the same day in many cases, which speeds up development and cuts down on guesswork.

    When to use FDM

    FDM printing is ideal for:

    • Early-stage prototypes
    • Functional tests (like snaps, hinges, or mounts)
    • Small-scale production (e.g. test kits or low-volume parts)
    • Jigs, fixtures, and workshop tools
    • Quick mockups to get client feedback

    Materials we use

    We print with a variety of thermoplastics, including:

    • PLA – great for fast prototypes and visual models
    • PETG – strong, durable, and slightly flexible
    • ABS – tough and impact-resistant
    • TPU – flexible rubber-like prints

    Not sure what material you need? We’ll help choose the right one for your use case.

    How we support it

    FDM is tightly integrated into our design process. We use it to:

    • Test ideas early and reduce development time
    • Validate designs before moving to CNC, casting, or moulding
    • Print custom parts or accessories for test setups
    • Bridge the gap between concept and production

    Need a part printed today? FDM makes it possible — and we’ll handle it in-house.

  • Prototyping – Testing the Real Thing

    You can look at drawings and 3D models all day, but nothing beats holding the real thing in your hands. That’s what prototyping is for.

    A prototype is a first version of your product — not yet perfect, but good enough to test, show, and improve. It helps us (and you) understand how it feels, how it works, and what needs tweaking before we move to production.

    Why prototyping matters

    Prototypes are a crucial step in product development. They let us:

    • Test how parts fit and move

    • Try out materials, buttons, hinges, and textures

    • Get real user feedback

    • Spot design flaws early

    • Pitch your idea to investors or partners with something tangible

    Different types for different stages

    Not every prototype needs to be perfect — and it doesn’t need to be expensive either. Sometimes a rough 3D print is enough to get answers. Other times we build detailed, high-quality models that look and work almost like the final product.

    Depending on your needs, we use:

    • 3D printing – for fast, affordable models

    • CNC machining – for functional parts in real materials

    • Vacuum casting – for small series or high-quality looks

    Prototyping helps us fail fast, learn fast, and improve fast — so when it’s time for production, we know we’re on the right track.