Prototyping for production FAQs

When designing and developing your components, developing a prototype is one of many critical steps towards a successful programme launch and efficient mass production.

How do you choose the right prototyping method?

While 3D printing is becoming increasingly popular, selecting a metal prototyping option requires careful consideration. It is essential to begin with the basics and assess the cost implications of various factors to achieve optimal long-term results.

The geometry, size and quantity of the final component are the primary factors influencing the choice of prototyping process because of their impact on cost. Specific features and properties may be better suited to one process than another. Additionally, it is necessary to determine whether the prototype will serve solely as proof of concept or whether a fully functional part is required for real-world testing.

Rest assured, a team of investment casting engineers can help determine the ideal prototyping option for any project.

Prototyping stage for alloy selection

The prototyping stage provides an excellent opportunity to test different material options. With investment casting, multiple material options can be explored during prototyping. For example, 3D-printed patterns can be used instead of traditional wax patterns, allowing engineers to print multiple patterns and run them through different moulds with different alloys to identify the best alloy based on the component's mechanical and physical properties.

Lead time for tooling and fixtures

With an in-house toolroom, tools and fixtures are built concurrently. The toolroom operates continuously, just like the foundries, ensuring there are no time gaps. As there is no reliance on external sources for tool manufacture, standard tooling lead times are three to five weeks.

In-house production machining capabilities

Both in-house production machining and machining for prototyping are available. A well-equipped machine shop houses three-, four- and five-axis machining centres with a wide range of capabilities. Plant tours are available for those interested in viewing the facilities firsthand.

Differences between parts made with manual tooling and production tooling

Generally, there are no significant differences. Manual tooling limits injection speed, so the main distinction lies in the injection rate. Fully production-ready tooling enables automated presses and robotic part removal associated with a full-scale investment casting production run. For higher-volume prototyping projects, a production tooling environment offers greater efficiency.

Available non-destructive testing (NDT) processes for investment cast prototypes

A variety of NDT procedures are available, including fluorescent penetrant inspection (FPI), magnetic particle inspection, X-ray, test bars, dimensional scanning and coordinate measurement (CMM). Regardless of the testing requirements, whether during printing or post-production, the resources and capabilities are in place to deliver functional prototypes.

Fully functional metal prototypes

Finding a supplier capable of consistently delivering effective prototypes is crucial. With investment cast prototyping, there is no need to compromise quality for time or cost.