Once you've decided on an idea and refined it into a final version of the product, it's time to choose the materials and manufacturing method for each piece. Modern trends suggest that manufacturers turn to aluminum alloys for prototyping metallic devices. These alloys offer a number of distinct advantages and there are numerous well-developed techniques for producing aluminum. Here are some reasons why you should choose aluminum processing as a method to produce your prototypes.
Excellent machinability
Machinability is a parameter that characterizes the machining efficiency of a given metal. It is calculated by dividing the current processing speed of the material by the processing speed of the sample material. The sample is usually some type of plain carbon steel. Now, if we compare the machining speed of an aluminum alloy to the machining speed of 1212 steel, we get 360%, which means you can cut aluminum 3.6 times faster than steel. Of course, steel can be stronger and more durable, but response time is more important in prototype production. You may sacrifice some shelf life to get the sample faster.
Aluminum alloys can be processed using a variety of techniques. Because they conduct electricity, some electrochemical and coating options are also available. Some of the most popular methods used by aluminum processing companies include CNC turning, CNC milling, grinding, polishing, honing, drilling and tapping, electrical discharge machining (EDM), electrochemical machining, grooving and more. Combining different techniques you can obtain a piece of practically any complexity and precision.
High precision and surface quality
Custom aluminum manufacturing is based on CNC machining, we call it CNC aluminum. Unlike other processes, there is no melting and subsequent solidification with the inevitable deformation that is characteristic of all thermal processes. CNC machining is the process that provides the best surface finish and tolerances. You can even get a mirror finish if you add a little polish. The maximum achievable tolerance when machining aluminum is IT8-7 and the surface quality is RA 1.25 mcm.
Easy casting and molding options
Aluminum alloys have the best casting properties. Therefore, if you have a master model of the part, you can easily obtain sand castings for small batch production. Shrinkage is minimal while fluidity is excellent. This means that the metal flows in the smallest details, while the shrinkage effect of solidification does not cause a major defect in the part. This allows you to significantly reduce material waste for batches of 10 or more.
The second way to process aluminum blanks is forming. Aluminum is very plastic, so you can hammer it into the desired shape by heating it. Today, hot forming is mainly associated with mass production in the die casting process, but there are also flexible tools and equipment that allow blacksmiths to change the shape of the blank without the need for special dies. A practical advantage is that molded parts have greater strength than standard parts.
Corrosion resistance
Aluminum manufacturers benefit from the alloys' corrosion-resistant properties. If you have a job where corrosion is a critical factor, you can simply choose aluminum and not have to worry about it. This metal forms an oxide layer on its surface that is just a fraction of a millimeter thick. This layer protects the metal from harmful external influences. No coating or painting is required to protect the piece from rust. And when applying a coating or paint, the part is almost insensitive to any type of external corrosion.
Great weight/strength ratio
Aluminum alloys are three times lighter than steel. This is why they are often used in the aerospace industry. Despite its light weight, many alloys are modified so that aluminum reaches the strength of steel. Therefore, if you want to make a product where weight is a crucial parameter, such as a portable device or an aircraft, you should choose aluminum alloy not only for the prototype but also for the final part.
Non-magnetic alloy
Aluminum alloys do not react to magnets. Generally this is an unimportant factor, except in cases where insensitivity to magnetic fields is the necessary parameter for the device to function. There are certainly other alloys that are passive to magnets, but aluminum is one of the cheapest and strongest alloys. Choosing a device case or device that cannot be magnetized is a good and economical option.
Medical use
It is not widely known that some aluminum alloys can be used in the medical industry. For example, alloys 6063, 6061 and 3003 are fully compatible with human tissue. Medical device manufacturers have a limited selection of biocompatible metal parts, and aluminum alloys are an affordable option. Another option is titanium. Titanium alloys are difficult to machine, while aluminum processing is efficient and easy.
High conductivity
Copper is the most common choice for wiring and electrical devices. However, copper is soft, expensive and has insufficient corrosion resistance. Aluminum compensates for all of the disadvantages mentioned above while also conducting electricity as well as copper. Therefore, using aluminum to make electrical device prototypes can be a sensible choice, especially if you need to make some complex electrodes.
Recycling Options
Modern industry strives to be environmentally friendly and sustainable, polluting the atmosphere as little as possible. Over the years, this factor has become increasingly important in the selection of product materials. This is why polymers and plastics are no longer used as standard. After all, it can be a hassle to dispose of plastic parts when the product serves its purpose. Often, recycling industrial-grade plastics is a complex and expensive process. Simply burning them or storing them in scrapyards is not the best solution. Therefore, manufacturers look for other materials to become more environmentally friendly.
Aluminum alloys are definitely in the environmentally friendly trend. They can be fully recycled. They can be easily melted and used in the next piece without creating waste. Additionally, you can cover part of the aluminum manufacturing costs by selling chips that you receive when producing your prototypes or small series.
