Functional validation of parts and assemblies
Verification of fits, assembly interfaces, assembly tolerances and functional behaviour with the final material and process.
Functional validation with industrialisable prototype moulds to make decisions before manufacturing the production mould.
Pilot2Plant (P2P) is ITM's prototyping service using industrialisable prototype moulds. Its goal is to obtain a minimum batch of injection-moulded plastic parts — with the final material — to validate design, process and tolerances before committing to the production mould.
The system is based on the combination of a standardised mould base with a machined insert tailored to the part geometry. The mould base acts as a reusable structural support; the insert reproduces the cavity geometry with the dimensional precision required for functional validation.
Unlike prototyping by 3D printing or direct machining, Pilot2Plant reproduces the actual injection process: material shrinkage, fill behaviour, ejection and dimensional stability. The result is parts that behave like production parts, not geometric mock-ups.
The service covers everything from the technical brief to delivery of the minimum batch with a results report, including DFM, insert design, machining, assembly and injection.
Not all prototypes provide the same level of validation. The Pilot2Plant approach goes beyond geometry and validates the actual behaviour of the injection process.
| Validation criterion | Traditional prototype | Pilot2Plant (P2P) |
|---|---|---|
| Geometry validation | ✓ Yes, validates shape | ✓ Yes, validates geometry + process |
| Material | ✗ Simulated / substitute material | ✓ Real plastic material (specified) |
| Process behaviour | ✗ No process behaviour | ✓ Real injection process |
| Material shrinkage | ✗ Not reproduced | ✓ Reproduced per material |
| Warpage and distortion | ✗ Not evaluable | ✓ Evaluable on injected part |
| Dimensional stability | ✗ Limited / not representative | ✓ Representative of production process |
| Transition to production mould | ✗ Partial, with uncertainties | ✓ Direct — transferable process data |
A structured workflow from the technical brief to delivery of the minimum batch with a results report.
Part definition, material, validation objective and required minimum batch volume.
Selection of the standardised mould base compatible with the geometry, material and process conditions.
DFM engineering applied to the insert: cavity design, feed system and ejection adapted to the process.
Manufacture of the insert to the required tolerances and integration into the standardised mould base.
Production of the minimum batch of parts injected with final material, results review and delivery with technical report.
Pilot2Plant does not compete with 3D printing or machining. It is the only option when the goal is to validate a plastic part with the real material, the real process and industrial tolerances before manufacturing the production mould. It reduces the risk of costly corrections in advanced project stages.
The minimum batch obtained allows functional assembly tests, performance testing, customer approvals and CTQ criteria definition before committing the investment in the production mould.
| Criterion | 3D Printing | Machining | Traditional prototype | Pilot2Plant (P2P) |
|---|---|---|---|---|
| Final material | No | No | Partial | Yes |
| Process validation | No | No | No | Yes |
| Industrial tolerances | Limited | Yes | Limited | Yes |
| Iteration speed | Fast | Medium | Slow | Medium-fast |
| Unit cost | Low | High | Medium | Medium |
| Transition to production | Not direct | Complex | Partial | Direct |
Processable materials, achievable tolerance classes and surface finishes available in the Pilot2Plant service.
Final material per customer specification. Option to use the same material grade as the production mould.
Achievable tolerances depend on part geometry, material and nominal dimensions. Applicability should be confirmed based on the specific design.
Surface finish is defined during the technical brief phase and applied to the machined insert before assembly.
Pilot2Plant is the right solution when geometric validation is not enough and the actual behaviour of the injected part is required.
Verification of fits, assembly interfaces, assembly tolerances and functional behaviour with the final material and process.
Mechanical, thermal or chemical compatibility testing with the exact material grade that will be used in production, not substitutes.
Evaluation of geometry industrialisation — ribs, wall thicknesses, radii and gate locations — on real parts before defining the final mould.
Preparation of the technical file for the production mould: process parameters, CTQ criteria, dimensional reports and customer approvals.
The Pilot2Plant service integrates ITM's quality management system, certified to ISO 9001. Each project includes a control plan with CTQ characteristic definition, selection of critical measurement points and inspection methodology.
Delivered parts are accompanied by a complete dimensional report, measured with calibrated internal metrology instrumentation.
Process traceability covers everything from the material grade to the injection parameters recorded during batch production, enabling reproducibility and direct transfer to the production mould.
Tell us about your project. Our technical team will assess feasibility, materials and indicative cost for the prototype batch.