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.

Having your part fail in prototype testing may seem like a minor catastrophe, but in reality it is a blessing in disguise. It is better to discover part weaknesses in the prototype process than in the production process, with hundreds, if not thousands of parts out in the marketplace. After all, prototyping is done to test the design.

Let us assume for a moment that heat dissipation is critical to your part’s performance. What if your part overheats in prototype testing? The problem could be in the design, but it could also be in how the prototype is cast and how the test is conducted. Before you rush back to the design computer, take a close look at the prototype itself. In what metal was the prototype cast? Does the casting accurately reflect the characteristics of a production casting? Remember, the prototype casting is only a simulation of the production casting. Take the time to examine the details of the prototype process that is being applied to ensure an accurate simulation. To modify the design without thoroughly analyzing all the issues relating to your prototype may cause you to over-design the part, which may lead to other complications in the production process.

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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