Home Case WorkDesign, rapid prototyping and production of fenestration systems.
Fenestration Systems
Design, rapid prototyping and production of fenestration systems.


We have a well-established working relationship with this customer. We provide three types of service; Design and manufacture of drill jigs; Design and manufacture of moulding tools; and product/component prototyping and volume manufacture. We support their in-house design team with our own expertise and in-house resources flexibly, collaboratively and economically, getting to the heart of their briefs and inventing ways to bring their ideas into being.


  • Challenge

    Our client is the largest privately-owned commercial fenestration systems company in the UK, and winners of a prestigious architectural design and innovation award. With a solid relationship going back to 2010, we work as an extension of their team. Briefs cover three types of service - end to end design and manufacture of drill jigs, end-to-end design and manufacture of moulding tools, and product/component prototyping and manufacture.

  • Solution

    Drill jigs and moulding tools, which make the manufacture of components economically viable, could involve up to six months of prototyping and modelling. They are designed in CAD, prototyped and then put into volume production using CNC machinery. We work with specialist designers to produce the moulding tools. These services feed directly into the production of aluminium extrusions - machining, cutting, tapping, pressing and fabricating using our 3 and 4 & 5 Axis CNC machine centres.

  • Outcome

    We supply our customer with thousands of aluminium components for their commercial fenestration systems each month. As designs change, our brief change to which we have to be responsive. We design, rapid prototype, commission mould tooling and run product manufacture in our in-house moulding department on a rolling basis.

  • Quality from start to finish

    "We have worked closely with Fabricon Design for over nine years on numerous engineering projects. Keeping manufacturing and design close together enables faster solutions and finished products are delivered promptly. We know the importance of exceptional workmanship and Fabricon ensures quality from start to finish."
    Mark, Technical Director at Fenestration Systems.

Lets talk