A prototype is a physical model or sample created to verify a new design, concept or process at an early stage. Prototypes are used in a variety of industries, including automotive, aerospace, medical technology, electronics, and architecture.
The role that metal prototypes play in our society cannot be overstated. They are so important that every product we use on a daily basis starts with them. Because the prototyping process is the step between evaluating and finalizing a new idea.
What is a metal prototype?
A metal prototype is an object used as a sample or model of a new product. Prototyping allows manufacturers and designers to transform an idea or concept into a physical object. The object can then be used for testing, demonstration, or additional design work as part of the product development process.
A metal prototype can be made using a variety of methods, including 3D printing, CNC machining, casting, sheet metal prototyping, etc. These prototypes can be made from many different materials, but the most common are aluminum, carbon steel, sheet metal, brass, copper, and bronze used.
Application and function of metal prototypes
1. Metal prototypes are used in a variety of industries made from different metal materials. They can be used in the construction industry to construct models of new buildings or bridges, or in the automotive sector to test cars or trucks.
2. In manufacturing processes, liquid metal is also used to create prototypes or test models of new tools, fasteners, electronic devices, or household items.
3. Manufacturers can use the prototyping process to test and refine new tools before beginning full-scale manufacturing. A metal prototype can take many different forms depending on the developer's goals. It may simply serve as a physical representation of the planned object, without any actual functionality.
Some prototype models may have full functionality and perform exactly the same tasks or actions as the proposed object. For example, a metal prototype for a new portable device may consist only of a hollow casing from which detailed prototypes can be made.
4. Metal prototypes offer many advantages for manufacturers and designers. They can be used to test designs or functions so that the manufacturer can improve the product before production begins. They can also be used to attract investors or potential buyers to a new product.
Why choose metal prototype manufacturing?
After deciding to make a quick prototype, another question arises: should I make a metal or plastic prototype? Compared to plastic, the metal rapid prototyping process offers some competitive advantages. To know the benefits, let’s take a look at the following points:
1. Excellent strength
Stainless steel, aluminum, titanium and magnesium alloys have some excellent properties, one of which is their strength and durability.
If the part being designed is exposed to extreme conditions such as intense heat and wind and has to support heavy weights, this is the perfect solution as most plastic parts simply are not as strong and durable.
2. Incredible value for money
Intuitively, we might think that plastic is cheaper than metal, which is true to a certain extent. However, plastic components wear out faster and must be replaced sooner.
Another reason why it is more economical to make the part from metal instead of plastic is the unique structure. Therefore, in some cases the metallic prototype is more promising and competitive than the plastic one.
3. Metal surface
If you want a metallic, smooth and shiny surface, this is definitely the right choice. Additionally, metal prototypes can be anodized to provide a corrosion-resistant finish, while plastic prototypes can only be painted. This also makes metal prototyping unique.
4. Versatile applications
The metal material itself offers more design freedom and can be used in many areas. In both the prototype and production phases, metal is preferable for functional and aesthetic reasons.
4 methods to make your metal prototypes
There are different methods for creating metal prototypes, and just like every coin has two sides, different methods have different advantages and disadvantages. In metal rapid prototyping, these technologies include CNC machining, metal 3D printing, sheet metal fabrication, metal casting and other processes. Let's now look at the advantages and disadvantages of each procedure.
1. CNC machining of metal prototypes
CNC machining (computer numerical control machining) refers to a computer-aided manufacturing process that uses common pre-programmed software techniques to control the entire movement of production equipment.
Materials suitable for CNC metal machining include aluminum alloys, copper, steel (especially stainless steel), titanium alloys, zinc alloys, and magnesium alloys. Although it is a popular manufacturing process, the advantages and disadvantages are still unknown to some.
Some CNC machines only work in the X and Y planes, while others work in three dimensions (X, Y, Z planes). Normally in a CNC workshop you will find 3, 4, 3+2 and 5 axis machines as the best solution.
Main advantages:
No Minimum Quantity – Since no mold is required for CNC machining, there is no minimum order quantity. Therefore, the unit prices of 10 pieces and 30 pieces are very close to each other. If you want to produce metal components in small quantities, CNC machining is the perfect option for you.
More Material Options – As mentioned above, there are a wide variety of metal blocks to choose from. However, aluminum, steel and copper are the most commonly chosen because they offer excellent mechanical and thermal properties.
High precision – The medical, aerospace and robotics industries are often high-tech and the components used there must be highly precise. They can be complicated, highly accurate and robust.
Disadvantages:
Higher unit costs – Although CNC machines can produce high-precision products, this can be time-consuming for complex projects. Unlike casting or printing, it is expensive if the quantity is large. In these cases, CNC machining is not recommended if there are no surface and precision requirements.
Material waste – it is a subtractive manufacturing process for mass production, which means that some material is removed from the metal blocks, so material waste is inevitable.
2. Metal prototypes for 3D printing
Metal 3D printing, also known as additive manufacturing, is a technology for building physical objects by printing layers of adhesive materials, such as metal powder or plastic powder, from digital model files.
3D printing is considered a new star in the manufacturing industry and acts as an additional or alternative technology. It has experienced rapid growth in recent years. It is generally suitable for light and complex individual parts with a short service life.
Main advantages:
Freedom of design – Recesses and internal structures are difficult to CNC machine, so 3D printing is the only method to produce very complex features. It allows designers and engineers to create a physical prototype without design limitations.
Fast response time – In addition to design freedom, 3D printing offers another advantage: the production of a metallic prototype in a short time. It is suitable when a short production time is required, especially for design projects.
Disadvantages:
Rough surface texture – Compared to CNC machined parts, 3D printed metal prototypes are less stable and have a rougher surface finish. You can feel the rough sensation and see the uneven surface.
Low-cost efficiency – Although 3D printed plastic products are quite common nowadays, metal 3D printing is not as common because the metal powder used for printing is expensive. This contradicts the business model where profit is most important.
3. Die-cast metal prototypes
It is a process for forming rigid metal castings. Molten metal is poured into a mold. As the metal and mold cool, the metal part is removed from the mold and transferred to the next round.
This process has been used for thousands of years and is still growing in popularity. Precision casting is an economical method of producing large quantities of complex shapes and designs.
Thanks to technological developments, it is now possible to produce molds through 3D printing or machine them using a CNC machine. This allows prototypes to be produced more economically and quickly.
Main advantages:
Production Quality – Sometimes our customers contact us for a metal prototype, but request metal casting when they proceed to mass production. Therefore, if the final products are manufactured using the casting process, prototypes guarantee production quality. You get something functional and solid that's worth the price.
height and weight – If you want to build a 20-foot metal prototype, casting is your only option. It's very big, so it probably can't be made using CNC or 3D printing. Size and weight are not limited to casting. This can be used to make anything from a small desktop device to a factory desalination tank.
Disadvantages:
High mold costs – Although the mold can be saved for future use, the mold cost is too high for low-volume metal prototyping projects. It's more of a mass production technique.
Rough surface finish – Cast metal prototypes have a relatively rough surface, so greater tolerances must be taken into consideration. This is not suitable for prototypes with matching surfaces.
4. Sheet Metal Prototypes
Sheet metal processing is another method for producing prototypes. Sheet metal prototyping involves placing standard thickness (usually thin) sheet metal on a table where a laser cutter uses a program to create patterns.
Various forming processes such as pressing, bending, punching and welding are then carried out depending on the geometric requirements. The sheet metal prototype is suitable for enclosures, panels and structural structures.
Main advantages:
Cost-effective – Due to the short delivery time, sheet metal prototyping is a machining process that provides high-quality parts.
Interchangeable- One of the biggest advantages of sheet metal is the ability to replace it. If several components are used for assembly, the individual parts can be removed and replaced with new ones. This saves costs, especially when changes or adjustments are required.
Production quality – Because prototyping is a step between design and the final product, production quality is important for testing the product, and sheet metal prototypes are generally of the quality of final products
Disadvantages:
Limited design freedom – Unlike CNC or 3D printing, sheet metal prototyping does not offer as much design freedom.
Greater dimensional tolerance – Compared to other metal machining processes, these tight dimensional tolerances cannot be achieved with sheet metal prototyping.
In short, if you need fast turnaround time and low cost, 3D printing is the best option. However, if you require a high level of precision or complex geometry, CNC machining is the best choice. Metal casting and sheet metal prototyping are good options for large or complex parts. Regardless of which method you choose, be sure to work with a qualified prototyper to get the best results.
6 Important Considerations for Rapid Metal Prototyping
1. Material properties : When prototyping with metal, it is important to consider the mechanical and physical properties of the material. Different metals have different strengths and densities.
Metal rapid prototyping materials can be manufactured through the use of CNC machines, direct metal laser sintering, laser cutting or printed parts for a perfect design.
2. Machinability : The machinability of a metal refers to its ability to be cut or shaped using machine tools. Some metals are easier to machine than others, meaning they are easier to form into the desired shape.
3. Toolmaking : To make a metal prototype, you need special tools. These tools can be expensive and not readily available. It is important to consider whether cost and tool availability will be an issue before selecting a metal for the prototype.
4. Surface Finish : The surface finish of metal parts can be an important consideration during prototyping. Some metals have a rougher surface than others, which can affect the appearance and function of the prototype.
5. Cost : The form and nature of the subtractive or additive process of a prototype determine its delivery time; Complex projects take more time. The cost of prototyping with metal can be significant, especially if special tools are required. It is important to consider material and manufacturing costs before choosing a metal for rapid prototyping.
6. Volume and budget : Mass production volume can be customized according to your budget and suitable method above.
University Degree
In short, metal prototypes are an important step in the product development process. They allow you to test your design and make any necessary changes before proceeding with manufacturing.
Plus, you can save time and money by identifying potential problems early. Understanding the benefits of metal prototypes can help you ensure your product development process is as efficient as possible.
With modern equipment and a team of highly qualified professionals, WaKen specializes in rapid plastic and metal prototyping. From tight tolerance CNC and custom surfaces to 3D printing with complex geometries and fast, cost-effective tooling, we can help you increase agility at every stage of the product lifecycle. Contact us today for more advice on your projects!
