Prototyping for Production FAQ

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

How to choose the right prototyping method?

While 3D printing is gaining popularity, selecting a metal prototyping option requires careful consideration. It's essential to start with the basics and evaluate the cost impact of various factors for optimal long-term results.

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

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 offers an excellent opportunity to test different material options. With investment casting, multiple material options can be explored during prototyping. For instance, 3D printed patterns can be used instead of traditional wax patterns, allowing engineers to print multiple patterns and run them through different molds 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 tool room, tools and fixtures are built concurrently. The tool room operates continuously, just like the foundries, ensuring no time lapses. Since there's no reliance on external sources for tool building, 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 centers with a wide range of capabilities. Plant tours are available for those interested in seeing the facilities firsthand.

Differences between manual tool and mass production tool parts

Generally, there are no significant differences. A manual tool limits injection speed, so the main distinction lies in the injection rate. A fully productionized tool allows for automated presses and robotic part removal associated with a full-fledged investment casting run. For prototyping projects with higher volumes, a production tool environment offers greater efficiency.

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

A variety of NDT testing procedures are available, including fluid penetrant injection (FPI), mag particle inspection, X-ray, test bar, dimensional scanning, and coordinate measuring (CMM). Regardless of the testing requirements, whether during printing or post-production, 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's no need to compromise quality for time or cost.