What is a quick and low-cost way of prototyping an aluminium die casting? It is approximately 30cm x 30cm x 8cm, and has heatsink fins on one side. Wall thickness of 2.5 or maybe 3mm

Is there a suitable rapid prototyping method, or should I consider sand-casting or alternatively machining from solid?? :?:

Thanks

 

It all depends what you want your prototype to do. Appearance model? You could get away with an SLA in plastic. Or fully functional? ProCAM, or zcastings.

Think about your design, will it be easy to design for the prototype and minimal redesign for mfg process. Casting involves drafts whereas machineing does not.

Mark

 

I'm not certain of aluminum properties, but 3mm thickness is marginal in the iron/steel process. 3.175mm would be minimum. The "V" process has been very successful in aluminum at minimal thicknesses such as you require.

 

I would recommend a plaster mold gravity cast process. They can use a variety of different master patterns to create the plaster mold, including wood, metal or SLA's. This will get you the closest to die casting as you will get without actually die casting. The finished parts will have very close mechanical and surface finish compared to the die casting.

Hope this helps

Kinnavate

 

How about laser sintering? Don't know if the price has come down since we used it a few years ago but it is a quick process. Saw some in action at the K-Show in Dusseldorf last week - very impressive.

 

Check this out. I've used it before with good results
http://www.scicontech.com/castings.htm

 

The best method would be machininig this process. sand casting wont be a good solution on this case, ofcourse i tired one of my aluminum die casting in this way only for proto device presentation.

 

This is especially true for die cast components where tooling prices can run into six Plaster mold provides initial prototype aluminum or zinc castings in a few. I would recommended plastic mold gravity, The best rapid prototyping and rapid injection molding company in China. Rapid Plastic Injection Molding · Rapid Pressure Die Casting

 

Hi,

Working with fast turnaround telecomms products, I have been rapid prototyping (die casting) designs of similar sizes and larger for a while. CNC "machined as cast" will give you an accurate model with appx 2 weeks lead time, depending on who you use. I have found that rapid prototyping houses using gravity casting do not give acceptable results... I use NADCA standards for die casting designs, and have had no problems so far going from machined to soft tooled and hard tooled die castings.

3mm wall thickness is perfectly acceptable for both aluminium and magnesium castings. Your mould tool designer should advise on any geometry changes after a mould flow analysis...

 

Why not you do it with cnc machining?