Shenzhen Alu Rapid Prototype Precision Co., Ltd.

1.Process Overview:

A mold is created, often using rapid prototyping techniques like 3D printing or CNC machining.

Molten metal (e.g., aluminum, zinc, magnesium, or steel) is poured into the mold.

The metal cools and solidifies, forming the part, which is then removed and finished (e.g., machined, polished).

2.Mold Creation:

Rapid Tooling: Molds are made from materials like sand, resin, or even 3D-printed polymers for temporary use, bypassing the need for expensive, production-grade steel molds.

3D-Printed Patterns: Wax or plastic patterns for investment casting can be 3D printed, speeding up the process.

CNC-Machined Molds: For higher precision, molds can be machined from aluminum or soft metals.

3.Types of Rapid Metal Casting:

Investment Casting (Lost-Wax): A 3D-printed wax or resin pattern is coated in ceramic, melted out, and replaced with molten metal. Ideal for intricate, high-precision parts.

Sand Casting: Uses 3D-printed sand molds or patterns for larger, less complex parts. Cost-effective and fast for prototypes.

Die Casting (for Prototyping): Molten metal is injected into a reusable, rapidly produced mold. Suitable for testing production-ready designs.

Plaster Casting: Uses plaster molds for non-ferrous metals like aluminum, offering smooth finishes for small runs.

4.Materials:

Common metals include aluminum, zinc, magnesium, brass, bronze, and low-melting-point alloys.

Steel or titanium may be used for specific applications but require more complex processes.

5..Advantages:

Speed: Molds can be produced in hours or days, with casting completed in 1–2 weeks, compared to months for traditional tooling.

Cost-Effective for Low Volumes: Avoids high tooling costs of mass production, ideal for 1–100 parts.

Functional Prototypes: Produces parts with material properties close to final production components.

Complex Geometries: Investment and sand casting support intricate shapes.

Scalability: Prototypes can inform production processes like die casting.

6..Limitations:

Accuracy: Less precise than CNC machining (tolerances typically ±0.1–0.5 mm), often requiring post-machining.

Surface Finish: May need secondary processing (e.g., polishing, sandblasting) for aesthetics or precision.

Material Restrictions: Limited to metals compatible with the mold material and casting method.

Mold Durability: Rapid molds (e.g., 3D-printed resin or sand) are single-use or limited to small runs.