Aluminum is the most commonly used material for manufacturing prototypes. Industries such as aerospace, medical technology and the automotive industry require long-lasting mechanical and structural components. Aluminum prototypes are robust, have excellent weldability and are resistant to corrosion, which makes them indispensable in the manufacturing industry.
Manufacturers use different techniques to create an aluminum prototype. Depending on the part, quantity or geometry, you can choose between 3D printing, CNC machining, aluminum casting, extrusion or sheet metal processing.
Let's look at the processes involved in each of these techniques to help you choose the best method for your prototype.
3D printing
This process is a popular choice for metal prototyping. Prototypes can be created using selective laser melting (SLM) and direct metal laser sintering (DMLS). Furthermore, 3D printing is cost-effective and involves additive manufacturing processes.
Similar to CNC machining, digital blueprints are used to make changes. Most aluminum prototypes require complex designs as they are constructed layer by layer. 3D prototyping is practical due to its geometric flexibility.
Due to the low costs and design freedom, you as a manufacturer can choose this technology.
CNC processing
Most aluminum prototype manufacturers use CNC machining. Using CNC-controlled machine tools, this method produces prototypes in the shortest possible time and with high precision. Furthermore, this method is convenient because it allows you to modify digital CAD designs.
Although this process is compatible with most metallic materials, it works best with aluminum alloys. Furthermore, as it is a subtractive manufacturing process, it leads to material waste.
CNC machining uses 4- and 5-axis CNC machines to create complex parts with detailed features.
Sheet Metal Prototyping
This manufacturing is a set of processes that includes forming, cutting and assembling aluminum sheets. It is used to produce functional prototypes, such as housings and industrial parts.
When creating a working metal prototype, manufacturers use laser cutting, stamping, bending and welding processes. To maintain quality, it is beneficial to use the same sheet metal processing techniques in prototyping and production.
The disadvantage of this technique is that it can be more expensive than other procedures if multiple techniques are required. For example, a single part may require a laser cutter and a punch press, while CNC machining requires just one machine.
You may choose this method if you need a series of manufacturing services or multiple copies of prototypes.
Cast aluminum
Casting involves pouring molten aluminum into a mold to create a prototype. As it requires specialized equipment, the mold making process is expensive. For this reason, this process is best suited for mass production.
Manufacturers can integrate 3D printing and CNC machining into the casting process to reduce metal prototype production costs. However, the production quality is good and produces robust parts that customers can use in various industrial applications.
aluminum extrusion
Ideally, extrusion is not viewed by manufacturers as a prototyping process, but rather used to produce original parts. Extrusion involves forcing materials through an open molded die to produce an elongated part.
Aluminum prototypes that manufacturers can produce using this process include metal rods, brackets, and connectors. However, due to high costs, most extrusion companies specialize in large orders.
Advantages of aluminum prototypes
Prototypes can be made from different materials depending on the part, functionality and strength requirements. However, aluminum is preferable for aesthetic and functional reasons. Here are some benefits of choosing an aluminum prototype.
· Superior functional performance
Although some prototypes have no mechanical or functional function, others must be used. Pre-production, hybrid and functional prototypes have a role to play and, therefore, must be of good quality and resistance. Aluminum is the preferred metal due to its superior properties.
Greater heat resistance
Compared to cheaper options such as plastic, the aluminum prototype is more resistant to extreme temperatures. Therefore, it is less susceptible to wear and tear during production.
· Better aesthetics
Whether you use 3D printing or CNC machining techniques, metal prototypes look better. Furthermore, compared to plastic parts, they are also more attractive as non-functional prototypes.
· Cost benefit
Aluminum prototypes and metal parts are significantly cheaper compared to plastic parts. This is due to the physical properties of the metal, which reduce the frequency of replacing parts. In the long term, this reduces production costs.
· Test accuracy
Prototypes made using processes such as CNC machining have a high level of precision. Furthermore, aluminum alloys are of the highest quality, so they can be used in the production of parts that can be used on the market for testing purposes.
· Best for mass production
Once engineers create an aluminum prototype, the customer can use it for production. It is easier to convert a metal prototype into a finished product. However, if the prototype is made of plastic, it cannot be converted to metal during mass production.
· Increases investor interest
Due to the aesthetics of aluminum prototypes, the product will attract more people. This increases the chances of early investment. As a result, the product can achieve significant commercial success.
· Superior strength
Aluminum alloys have high strength, good corrosion resistance and good formability. Due to these excellent properties, they are widely used in most industries. For example, aluminum parts are commonly used in the aviation industry. Due to this strength, customers can count on high-quality parts and prototypes.
Summary
Prototyping companies use aluminum in most of their processes due to its superior properties. The demand for these parts in most industries has made aluminum prototyping one of the most popular processes in manufacturing. Depending on the parts you need and your budget, you can choose from the above techniques for your prototyping.
