Isso torna a prototipagem de chapa metálica muito fácil

This makes sheet metal prototyping very easy

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Rapid prototyping is becoming more widespread as it proves its effectiveness on a global scale. This term emerged recently and was mainly associated with 3D printing, but once designers and product developers got the hang of it, the demand for fast technologies increased dramatically. For this reason, many other plastic and metal prototype manufacturing techniques are being developed, called rapid techniques. One of them is the sheet metal prototyping technique. Let's look at how cold sheet metal forming can be developed into a rapid prototyping method.

What actually is sheet metal fabrication?

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Sheet metal forming is an important tool in the production of thin-walled structures from metals with good formability. The main advantage of the sheet metal processing process over other “pressure” machining operations is that the blank does not need to be heated as in stamping. Thin sheets can be folded when cold. This leads to a fast, economical and sustainable manufacturing process. Many modern structures are made from sheet metal. Let's look at the car, for example. Its body is made entirely of sheet metal. This means that the weight of the cars is significantly less.

From sheet metal forming to rapid prototyping

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To understand what changes are needed to transform the traditional sheet metal manufacturing process into a rapid sheet metal prototyping technique, it is necessary to analyze where the most time-consuming steps occur. The main components of sheet metal forming are the following: A hydraulic (or other motorized) press to apply pressure. A matrix fixed to the press plate and having the aviary corresponding to the desired shape of the final piece. A punch is the part that presses the sheet metal and presses it into the die. The punch generally has a convex surface that matches the concave surface of the die. There are thousands of other specialized tools related to sheet metal fabrication, but they are used to support the process, not carry it out. Let's focus on the most important elements of the system.

Where Sheet Metal Prototypes Can Be Improved

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So how can we improve the process to turn it into a rapid sheet metal prototyping technique? First, the weakest link must be identified. In sheet metal forming, the time required to produce custom dies and punches determines the overall sheet metal prototype lead time. Dies and punches are usually made of heat-treated instrument steel, which is very difficult to process. The most efficient way to reduce lead time for sheet metal prototype parts is to reduce die and punch production. This can be achieved in several ways.

  1. Product life cycle management. Manufacturing tools are also products, and PLM is a product information support system that dramatically reduces time for R&D, product design review, resource management and planning, and NC program design. PLM integrates all individual phases of the product life cycle and coordinates the production of tools.
  2. Using simpler materials. In the rapid production of sheet metal prototypes, tools do not need to be particularly durable. Most product developers only need a few sheet metal prototypes for testing, so the die material can be much softer. For example, some aluminum alloys can be used. Dies made from such alloys are suitable for a limited batch, but this batch size may be sufficient for the durability of the die. On the other hand, a softer material means a significantly shorter delivery time to the die.
  3. Using modern CNC and CAM systems. Many shapes have complex cavities or many features. Manual processing would take too long or simply be impossible. This is why CAM systems are used. They allow manufacturers to create NC programs for any type of mold cavity.
  4. Use of interchangeable matrices. Dies typically consist of the base elements used to attach them to the press and the cavity used to form the part. To reduce processing effort, it is possible to produce the cavity separately. This way, the matrix is ​​composed of two parts and its precision is lower, but prototypes generally do not require perfect precision.
  5. Avoiding automation. Modern processes for mass production of sheet metal parts are highly automated and this is an advantage in the long term. However, automation takes time to set up and verify and only intervenes in prototype development. Therefore, it is really good to avoid extensive automation in such complex areas as loading and unloading parts, sorting raw parts, transporting parts from one machine tool to another, etc.

Metal prototyping services as a shortcut to rapid sheet metal prototyping

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Producing sheet metal prototypes is not an easy task. When you're just starting out, it can be difficult to master conventional forming to optimize sheet metal costs. To actually move on to more advanced sheet metal prototyping, you need to spend a lot of effort and money. But there is a shortcut.

If you are not sure whether you really want to enter the fast-turning sheet metal parts industry, e.g. For example, if you are a developer or designer and just want to create your product and get it to market faster without delving into all the steel, titanium or aluminum manufacturing processes, metal prototyping services can be an good solution for you.

Sheet metal processing service providers have the advantage of being able to buy cheap sheets at warehouse prices because they always require large quantities and sheet metal manufacturers give them a discount. They have state-of-the-art equipment and more experience because they make their money manufacturing sheet metal parts. You just need to provide a 3D model or design drawing and they can advise you on the best way to prepare it for manufacturing and create a prototype batch for you quickly.

Sheet Metal Rapid Prototyping at Wayken

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