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A lifesaving response – cutting delivery times by 90%

Formaplex cut normal delivery times by 90% and worked around the clock to provide essential components for a pioneering project team’s new ventilator.  It was part of an industry-wide response to help save lives during the COVID-19 pandemic.

The new ventilator was ready for production in just a few weeks, helped by Formaplex’s design for manufacture optimisation, 3D printed prototype components and production injection mould tools.

“Design, testing and delivery of injection mould tools for production can usually take up to 10 weeks. But our specialist task force delivered a suite of five tools and the first 100 parts in just eight days,” Adrian Chapman, Engineering Director.

Dominic Harris, Machining Manager is shown here with some of the 3D printed components.

Speed and accuracy

Speed and accuracy were of the essence to ensure the overall project’s success. The Formaplex team of designers, project managers, CNC machinists and toolmakers worked 24/7, including over the Bank Holidays. In order to comply with the strict social distancing measures, they worked in shifts on site and from home where possible, using the latest technology to keep in touch.



Fortunately ventilators have not been required in the numbers originally estimated by the Government. This means that the ventilator produced in this project will not be going into large scale production at this time.

The customer name is not included here for confidentiality purposes.

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