It is critical for customers to be confident in their design before going into production because die cast production tooling prices can range from six figures to seven figures depending on the complexity of the tooling.

• For the production of prototype aluminum die cast parts, there are four primary methods available: single cavity prototyping, plaster prototyping, machining from solid, and additive manufacturing

• Learn about the advantages and disadvantages of each method in the sections below so that you can make an informed decision when developing your next application

   

Plaster Modeling and Prototyping

Plastic mold die casting (also known as rubber plastic mold casting) is a method of producing aluminum, magnesium or zinc castings by pouring liquid metal into plaster (gypsum) molds. Plaster prototyping is also known as rubber plastic mold casting. It is not possible to use plaster prototyping if your application requires special alloys, such as 390 or 413 aluminum, for example. It is a popular choice among customers because it requires less initial tooling investment than a single cavity prototype die and can be completed in as little as two to three weeks. However, there are some limitations to this method that should be taken into consideration. Using high pressure, die cast parts are produced, whereas plaster castings are produced by gravity pouring. Consequently, the grain structure of the custom die casting is significantly increased, which has an impact on the mechanical properties. The mechanical properties of a plaster die casting aluminum are only 70% of those of a die-cast part, which is a significant difference. Testing your prototype may become more difficult as a result of this. If your part fails in the last 30% of your test, it can be difficult to determine whether the failure was caused by the prototyping method or whether your design requires revision.

Prototype with a single cavityIt is necessary to die

A single cavity prototype die allows for the production of a aluminum casting with mechanical properties that are identical to those of a production part. Single cavity prototypes are the closest representation of a production part that you can get without making a full-scale production part. Single cavity prototypes are made with the same production alloys, pressure, and rough cycle time as the final production part, saving time and money. The only difference between a single cavity prototype and the final production part is the presence or absence of cavitation in the prototype.

In contrast to production parts, prototype dies will only have a single cavity, whereas production parts may have several cavities. At General Die Casters, we frequently create low-cost unit dies for the purpose of die casting mould prototypes. These dies are made of soft steel, which allows for a shorter construction time and a lower overall cost of production. Our prototype dies were inexpensive and we have successfully cast more than 5,000 parts from them.

Machined Parts from Solid

Manufacturing from solid, also known as "hog outs," is a process in which the prototype part is CNC machined from a billet of aluminum or stainless steel. You can expect a turnaround time of 7-10 business days if you only require a few parts using this prototyping method. In comparison to the other prototyping methods we've discussed so far, machining from solid has a significant disadvantage in that it has the highest piece price of any of them. A die cast part's surface finish and mechanical properties cannot be replicated by machining from solid, and it is more difficult to create curved surfaces and radiuses in some geometries when machining from solid. This method has the potential to provide the lowest price point. A small number of prototypes may be required for your project.