We’d all like to think we can get it right first time, but few things are that straightforward.
Consumers are demanding, and in the world of manufacturing, mistakes can be costly – with anything less than perfection eating into time and money.
There are ways to avoid mistakes, though, and a strong argument for trial and error. Take the time to get things right now and you could reap the rewards long-term.
What is prototyping?
The leap from a design on paper to production is vast and fraught with risk. Get things wrong and the fallout will be hard.
To help bridge the gap, and reduce the threat of failure, prototypes are used.
Designed to replicate the final component as closely as possible, prototypes put designs through their paces, rigorously testing everything from functionality through to safety.
Why do you need prototyping?
Does your component demand specific tolerances? Do you need to test the strength of your part? Do wall thicknesses need to be checked to ensure a perfect fit?
These are just some of the things that need to be evaluated, and prototyping is a valuable aid to the process. Done effectively, it offers the opportunity to spot design flaws and counter potential complications – before committing to mass production!
If there is a problem, then the earlier in the process it’s identified, the better – this will help to minimise any impact on costs and timescales.
Not every design will require prototyping, but it can help in the pursuit of excellence. Testing may not identify a problem, but it could highlight a way things could be improved or further enhanced – helping to keep your design at the top of its game.
Prototyping for diecast parts
There are a number of methods for prototyping die cast parts. Examples include:
Spin casting – this has a low tooling cost and can offer wall thicknesses and surface finishes that are very close to your specifications. However, the mechanical properties will not be identical.
Sand casting – again, this has low tooling costs, but the capability to cast thin walls is restricted.
Investment casting – ideal when an exact copy is required. Using this method of prototyping will ensure your test component has all the same characteristics, including tolerance levels and strength, to inform detailed safety testing.
Machining from bar stock – this is preferable for speed and cost efficiencies when producing low volumes. The issue here is that the part’s ductility and tolerances will be limited.
Find the right prototyping process for your needs
Assessing the best means of prototyping for your needs requires careful consideration. It’s important to consider factors such as costs, capacity, timescales, wall thickness, dimensional accuracy, and surface finish.
If you’re unsure whether you require prototyping, or if you would like to know more about prototyping for diecast parts, then why not get in touch with the team here at Lupton and Place?
As industry leaders for aluminium die casting, we’re best placed to offer expert guidance, and will work closely with you through every stage of the process to ensure you achieve the optimum performance from your component.
Quality is the backbone of our business, underpinning everything we do. We won’t settle for anything less than the best – so why should you? Get in touch today to find out more.