Bob Kowalczyk
President & Founder

As a die casting engineer with more than 35 years of experience in prototype and low volume casting production, I have a deep appreciation and understanding of the challenges you, as a designer, face.

How will your part be used?

This is one of the most important questions to ask before beginning the prototyping process. The answer to this question may determine your choice of prototyping options. Below is a real-life situation where neglecting to ask this all-important question unfortunately resulted in a Career Limiting Decision (CLD).

Which prototyping process is right for you?

Every process has inherent advantages as well as limitations, and prototyping processes are no exception. New processes, materials and technologies have only served to add to the options and the pitfalls. Be sure to familiarize yourself with the pros and cons of the various prototyping processes available. And then clarify the reason(s) for creating the cast prototype before releasing the design for production.

Production determines the prototyping process

The operating parameters and characteristics of the eventual production process should be an integral part of the design process. This will help the designer throughout the design development. Keeping the production process in mind will guide design decisions as well as determine the prototyping process best suited to simulate the ultimate production part characteristics.

Enhancing Part Performance

Grain refining and heat treatment are just two of the tools and techniques used at Alumacast to create prototypes that perform mechanically as close as possible to the performance of the eventual die casting.

If you have concerns about a specific project or application call me at 920-596-1988, or send an email.

Do aesthetics matter in prototype castings?

Capturing the aesthetics of a finished die casting in the prototype process can be very important. Some prototype processes would not satisfy these specific requirements. Prototype castings produced with the Aluma Cast process not only perform like die castings, but also have the look and feel of a production die casting.

Test your prototype in two materials with one tool

Occasionally we get requests to produce prototypes in both aluminum and zinc. A little known fact is that at Aluma Cast we can cast parts in either zinc or aluminum from the same tool. If you have a desire to test the parts in both materials we can accommodate you with one tool for both materials. Call us if you are interested in exploring this option.

Aluma Cast offers a unique blend of artistry in metals and engineering expertise. The result is a deep appreciation and understanding of the designer’s work and the challenges he faces. Knowing that design changes are integral to the design/prototyping process, we make every effort to work with you to allow for changes ensure a successful end product.

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