Our Work:

Bell Helicopter Cowling – Composite Replacement
Working in association with an aerospace engineering company, we 3D scanned and CAD modelled the cowling from the original metal part. With the decision made to replace it with a composite version, careful consideration had to be given to the composite elements in the new design — ensuring structural integrity, weight optimisation, and compatibility with the existing airframe.
The CAD design was completed using the 3D scan as reference alongside the original Bell drawings, allowing us to maintain dimensional accuracy while adapting the geometry for composite manufacture.
The part is now in service on the helicopter.

The client required a complete tooling design for a composite dog bath, incorporating both inner and outer mouldings. Starting from a simple CAD concept, we developed the full 3D model including all fitments and tooling components — over 10 individual mouldings, all designed to fit precisely together. The CAD was used to produce the tooling and the part is now in its prototype / first-off phase, soon moving into full production.
Designed by Method CNC

Toyota Panel Van Sidepod – Design & Manufacture
To create this sidepod we 3D scanned the side of a Toyota panel van and modelled the part in CAD. Working closely with the client and checking against ADRs, we visualised the concept in 3D to refine the design before committing to tooling. The plug and mould were created in-house at Method CNC and the part is now in production.
Designed and manufactured by Method CNC

One of our earliest jobs together. The client wanted a lightweight back plate for their wheelchair that could be easily packed up and transferred between different chairs and seating setups.

We started by 3D scanning the existing back plate, then reverse engineered the geometry and 3D printed a mould. From there, we produced a finished carbon fibre part that was significantly lighter while still retaining the original fit and function.

At Method CNC, we specialize in designing innovative kits from flat materials to create finished products, molds, and patterns. By leveraging advanced modeling techniques and clever connection details, we’ve developed kits that can be assembled with precision sometimes in just minutes.

Whether you’re looking to develop a custom cut-on-demand product or a one-off kit, we can help bring your vision to life.

Our kits can include detailed assembly instructions and technical drawings to ensure a seamless build process. For more complex projects, we offer hybrid kits that combine CNC-cut parts with 3D-printed components and foam-milled elements to achieve the perfect balance of simplicity and sophistication.

conbining data from a drone scan and a lidar scan we prepared the cnc cut kit as well as the construction drawings and kerfed panel drawings for this transom extension

Starting off with 3d scanning the and coaming we design and fabricated a one off composite cabin top and hard top