Wire Spool Stress Balls
Alloy Wire International
Alloy Wire International is a world leading manufacturer of precision drawn round wire, flat wire, profile wire, bars and wire rope in more than 60 different high performance nickel alloys.
They were looking to get a unique promotional gift made and thought that a stress ball in the shape of one of their wire spools might just fit the bill.
READ THE PROJECT CASE STUDY
PRODUCT IMAGES SUPPLIED
To enable us to quote we were sent a number of photos showing the shape of a wire spool from all angles. The quote was approved and the order was sent through to begin with the tooling sculpture design.
HAND SCULPTURED RESIN DESIGN
The first stage of manufacture is to create a resin mould which is to be used to make the master tooling. This is sculpted by hand, using the photographs as reference to get the design as close as possible to the real item. Photos of the resin images were sent to the customer for approval where we could have made any tweaks to the design but as is often the case, no changes were needed to the sculptures.
PRE-PRODUCTION SAMPLES
Using the resin sculpture the master tooling was made so we could proceed with producing pre-production sample images. This is where a couple of fully coloured and printed stress balls are produced, with photographs sent to the customer to ensure they are 100% happy before we manufacture the bulk order. In this instance we hadn’t finalised the print so we explained the benefits of having the logo printed rather than embossed so that the logo could also be coloured. The customer agreed that printing was the best option so the samples were printed and sent for approval.
FINAL STAGE - BULK PRODUCTION
The customer was thrilled with the sample images and these were approved without any changes needed, however we could have amended the item colour or print at this stage if requested. With the stress wire spools approved they were sent for bulk production and then swiftly shipped to the customer for use.
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