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).
In the prototyping process there are things that can be done to give you sufficient quantities of production castings without breaking the bank.
These are the two most important words in prototyping.
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.
There comes a time when your production tooling May no longer be usable. What can you do? You only need a couple hundred parts, but your die casting die or permanent mold is no longer available. Aluma Cast’s low volume casting process may be a viable option for you.
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.
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.
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.
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.
Is the part you are designing going to be subjected to significant structural loads? Talk with Aluma Cast engineering about prototypes with enhanced mechanical properties.