Making a Metal Prototype: Nützlicher Leitfaden

The manufacturing process of components in different industries doesn't just start immediately. It requires the prototypes to be manufactured first.

Prototypes are a crucial part of the development stage when it comes to manufacturing metal prototypes. Some of the aspects to consider are featured in the guide below. So, let's read on.

What is a Metal Prototype?

Metal prototyping consists of creating a sketch of the metal product, which is done before starting the production. The designers test these models and, if required, update them.

Metal prototyping is a crucial process in most of the industries and it offers various advantages.

When Would You Choose Metal for Prototyping

Metal prototypes are created to check their functionality and performance. It is important to align them with the process of production.

Metal prototyping supports cost-efficiency and smooth development which helps to transform metal prototypes in the actual part.

Normally, plastics are chosen for prototyping but it is challenging to transform plastics into metals, and hence, converting metal models into metal parts is easier.

Benefits of Metal Prototypes

Metal prototypes have multiple benefits, and some of these are as follows:

• Metal prototypes have a high strength. Metals like stainless steel have a high hardness, which ensures high yield strength. These prototypes are durable and can withstand multiple conditions.
• Metals have high melting points, and they do not degrade over a period of time.
• Metal is cheaper compared to plastic when applied in different applications.
• Metal parts are aesthetically appealing and also compatible with finishing methods.
• Metal prototypes offer versatility; they can be subjected to a wide range of processes and, hence, it is compatible with multiple applications.

Common Metals Used in Rapid Prototyping

Schnelles Prototyping uses two of the most common metals, which are aluminum and steel. Other than these metals, other metals like copper, chrome, magnesium, and copper are also used.

Titanium is a metal that offers high strength and density, as well as a high melting point. Aluminum is also lightweight and offers high machinability. It even has multiple advantages which include scalability, corrosion resistance, and high electrical and thermal conductivity.

Magnesium alloys are also used for producing metal prototypes, and they can be used in applications that need low weight density and high thermal conductivity.

Steps of Making Metal Prototypes

The steps for making metal prototypes are the following:

• The first stage is the stage of designing; a sketch of the model is created either on paper or in the software. The CAD software is used for creating the visualization of prototypes.
• Select the metals you want to have the prototypes manufactured for, you have to choose depending on the application and properties you need.
• Choose the manufacturing process based on the lead time, cost, and the rolling method.
• Manufacture prototype through the selected process of manufacturing.
• Now, test and evaluate if it meets the required specifications and update accordingly.

How Do You Make a Metal Prototype?

There are different fabrication processes for making metal prototypes, and some of these processes are as follows:

CNC-Bearbeitung

CNC-Bearbeitung uses the process of CNC machines for manufacturing metal prototypes.

CNC machines use a subtractive process of manufacturing, removing metal, and then achieving the required shapes of the component. CNC machining is compatible with metals like aluminum, zinc, steel, and magnesium.

3D-Druck

3D-Druck is an efficient method for manufacturing metal prototypes. The process of 3D printing is an additive process that involves manufacturing components layer by layer.

It uses different technologies like DMLS and SLM. Using laser beams, they can create layers of parts using different metal powders. CAD design inputs to attain the required designs and helps achieve complex shapes and detailed features.

Herstellung von Blechen

Sheet metal prototyping is used for manufacturing parts using different processes. The process involves cutting, deforming, and assembling the sheet metal parts.

The process uses sheet metal plates on a flatbed to cut the shapes and achieve the required parts.

The process of sheet metal fabrication involves laser cutting, punching, bending, and welding. It can help create prototypes consisting of brackets, enclosures, and other parts.

Metallgießen

The process of metal casting is pouring molten metal into the molds, which have cavities, and creating the required shapes. Once the liquid metal material is solidified, the desired prototype is achieved. It is an efficient method of producing components of different shapes.

Aluminium-Strangpressen

Strangpressen von Aluminium allows the creation of properties with the dies, which can produce parts in a longer shape. These parts are cut to the required length after being extruded.

Aluminum extrusion is mostly opted for high-volume production but is also used for creating metal prototypes. Parts like brackets, joints, and metal bars are also manufactured.

Considerations for Making Metal Prototypes

When making metal Prototypen, some of the considerations are as follows:

Qualität

The quality of the metal prototype is compared with the final production, and hence, it is important to ensure that the quality of the prototype is up to the mark. It offers durability and ensures the desired surface finish.

Purpose

The purpose of metal prototypes is based on the product development stages; every stage has a specific functional requirement and desired features. It determines the prototype quality and impacts the function of the prototypes as well.

Part Complexity

The features of the prototype and its design complexity impact the selection of the process. Every process offers a different type of complexity. 3D-Druck offers a suitable process for complex components and CNC machining for parts with tight tolerance.

Menge

The prototype parts you require must be considered, too, when selecting the method for fabrication. Some processes are meant for less volume, and some for high volume.

Cost/Budget

When choosing the prototyping process for metal parts, make sure to consider the time and money that is spent on the manufacturing. Select the metal prototype process based on the budget you have.

Applications of Metal Prototype

Metal prototypes have various applications, and some of these are as follows:

Functional Testing: Metal prototypes are suitable for testing the durability and mechanical properties of the parts by subjecting them to real-world applications.

Structural Testing: Metal prototypes are also evaluated by subjecting them to heavy loads to check their load-bearing capacity.

Tooling: Prototypes for tools and molds are also manufactured to test them.

Schlussfolgerung

Understanding everything about metal prototyping is very important so that you can achieve the required components with no defects when you head to the final production.

Wir bei DEK offer you the opportunity to have metal prototypes created with complex shapes and features on an affordable budget. So, get in touch with us to have your hands on these prototypes.

FAQs

What are the methods for manufacturing metal prototypes?

The different methods for metal prototype manufacturing are CNC machining, 3D printing, sheet metal fabrication, and aluminum extrusion.

What is the purpose of metal prototyping?

The purpose of metal prototyping is to create models of the components that are to be used in different applications. Testing these prototypes helps to make improvements.

What materials are suitable for metal prototyping?

The metals suitable for prototyping metal parts are aluminum, titanium, copper, and stainless steel.