Solid models play a useful role in the engineering design world. There are many benefits to using solid models in the design process, not the least of which is the three dimensional perspective of the design. But as good as solid models are, they have their limitations.
During the course of completing the design for a heat-sensitive, thin-wall casting the engineer was mistakenly advised to thicken the walls of the part design from 3mm to 5mm to accommodate prototyping process limitations.
Aluminum alloys exhibit different heat transfer characteristics when die cast versus gravity cast. To compensate for that difference Aluma Cast Foundry has developed a heat transfer chart to demonstrate the alloy options available in order to more accurately simulate the heat transfer characteristics the part will exhibit as a production cast part.
Alumacast is following the developments in the application of nanotechnology in metal castings.
Besides making a handful of parts for testing, the prototype casting process is also suitable for low volume production.
Every process has inherent advantages as well as limitations, and prototyping processes are no exception. Understanding the capabilities of the process you choose will avoid undesirable surprises and allow you to achieve optimum results in minimum time.
It is an understood fact that the whole reason for prototyping is to ensure the best possible part design before committing to the cost of building permanent tooling. Design changes in the prototyping phase of product development can be a normal part of the process.
It is important to remember that the prototyping process is often being used to simulate a product die casting. Although this seems rudimentary and obvious to any designers of cast metal components, it does merit mention here.
The prototype process serves many functions, but seldom is it perceived as a way to minimize cost and save time in the production process. But approached the right way the prototype process can be instrumental in clearing your way to production, and it can minimize the cost of the production dies.
In the prototyping process there are certain features on a cast part that should be machined even though they will be cast in the production process. For example:
