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.

Let us assume that the decision has been made that a prototype will be needed before releasing a part for production. So the next question is what type of prototype will you need? Or to phrase the question another way, What is the primary reason for creating a prototype?

If you are working as a member of a design team, you may have one specific reason for wanting a prototype. Another member of the team may have a completely different reason. Be sure that everyone is in agreement on what needs the prototype will have to satisfy. Don’t assume. Assumption is the mother of many failures.

It is important to understand all criteria that are pertinent to each particular prototype. So you may ask yourself, Are we creating this prototype simply for appearance or “fit” only? Will this part be subjected to mechanical testing? Will we be testing for RF leakage? Is corrosion resistance an issue? Is weight and strength a linked issue? These answers to these and other related questions will guide you in the direction of the most suitable prototyping process and subsequently the success or failure of your project.

Some of the options available to you include but are not limited to Sand Casting, Plaster Mold Casting, Investment Casting, Machined Hog-outs, Direct Shell Casting, among others. Now, add to this mix of possibilities the attachment of one of the Rapid Tool options and you get a feel for how confusing a prototyping program can be.

New processes, materials and technologies have only served to add to the options and the pitfalls. If you are facing some tough decisions about a prototype you are contemplating, do not hesitate to give us a call. We are always glad to help any time.

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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