When communicating the requirements for your prototype, there is always the risk of either under-specifying or over-specifying. Too many details, and you may end up paying for more than you need. If you are dealing with a qualified, professional prototype supplier, make sure to provide enough details on the “must haves,” and trust them to use their expertise and proper judgement on these details.
New technologies have proven instrumental in facilitating the production of complex geometries by combining our conventional fine-grain sand casting process with 3D printed cores/molds. Used in combination this allows us to take advantage of some of the positive characteristics of each process.
Sometimes components are designed in advance of the production method chosen which on occasion places the designer and production team into a potentially compromising situation. Not knowing the production process while designing a part can create unwanted obstacles and at times unnecessary extra work and cost. As a prototype supplier we are in a unique position to guide the designer to the proper production methods allowing the designer to take full advantage of the characteristics of the eventual production process.
If you need to test the mechanical strength of the cast part, measure heat dissipation or any other mechanical properties you can only accomplish that with an actual metal casting. The software simulates the molten metal flow through the gating systems and how the metal fills the casting cavity of the mold. However, the software simulation can certainly help focus your prototyping process and ensure a successful outcome.
Contrary to popular misconception, thin-walled castings can be produced in the sand casting process. Thin-wall prototype castings can present a challenge in the prototype world, but that does not mean that thin-wall parts cannot be cast and properly tested in prototyping processes. If you have any concerns about the cast-ability of your thin-walled design, call us for a free consultation. Or contact us through this site.
Contrary to a common misconception, the sand casting process can provide the surface finish typical of die cast parts. Aluma Cast uses a fine-grain sand casting process designed specifically for prototyping die castings. Our typical as-cast surface finish is a 100 RMS.
Recently claims have been made that sand castings, when used to prototype die castings, require more draft than the eventual die castings.
In the design stage of the process, it may not be possible to anticipate what types of changes may develop along the way during a new product introduction. However, where there is the expectation of later changes, the prototyping process can be used to satisfy a variety of contingencies.
Recently someone asked how the Aluma Cast process works. “Precision Fine Grain” describes the variation on the sand casting process Aluma Cast uses to achieve high quality sand castings that simulate the die casting process.
The higher the quantity of parts to be produced the more production process options are available to you.