5 Methods For Making Aluminum Prototypes

Aluminum is a popular metal many manufacturers use in making prototypes and production parts because of its excellent mechanical properties. These prototypes are applicable in several industries for testing due to the need for quality and durable parts and aluminum prototyping is commonly used in such industries.

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Manufacturers employ various aluminum prototyping methods, each with pros and cons. Since the wrong technique can incur huge losses, this article discussed the common aluminum alloys used in prototyping, different aluminum prototyping processes, and how they can apply to your project.

Common Aluminum Alloys Suitable For Prototyping

Various aluminum alloys are suitable for prototyping, but some are more used than others. Common aluminum alloys used in industries such as automotive, aerospace, and medical part manufacturing include:

1. Aluminum

Considered the most common aluminum alloy used in manufacturing, aluminum contains aluminum and manganese, which helps boost its strength by 20% without damaging its flexibility. It is not heat-treatable. Nevertheless, it has many applications, such as its use in manufacturing utensils, aluminum storage tanks, etc.

2. Aluminum

This is another non-treatable alloy known for its strength and resistance to water and chemical corrosion. As a result, this makes it applicable to producing marine parts and equipment.

3. Aluminum

This heat-treatable aluminum alloy contains magnesium, silicon, chromium, and copper. Aluminum has high tensile strength and great corrosion resistance and is applicable in making electronic and automobile parts.

4. Aluminum

Aluminum is heat treatable like aluminum and has zinc as its major alloying element alongside other elements such as manganese and copper. It is lightweight and strong. Hence, it is applicable in the aerospace industry in manufacturing gears and fittings for aircraft.

5. Aluminum

Also known as architectural aluminum, Aluminum comprises silicon, copper, and magnesium. It has moderate strength and being a silicon-magnesium alloy, it can resist corrosion well. As a result, it is applicable in making parts used externally, such as architectural components, pipes, and furniture.

Different Methods for Making Aluminum Prototypes

Various methods can be used to make an aluminum prototype depending on the part function, quantity, and geometry. The most used techniques are:

Method #1: CNC Machining Aluminum

CNC machining is a common aluminum prototyping method that uses computer inputs to accurately control the machining tools and eliminate parts of the aluminum workpiece to achieve the desired aluminum CNC prototype. It comprises several techniques including CNC milling and CNC turning.

The benefits of CNC aluminum machining include:

• High compatibility with many aluminum alloys.
• The parts produced using this method display excellent attributes and a good surface finish.
• It is suitable for making prototypes with complex designs.
• High precision and accuracy.
• Easily change the design between prototypes without altering the lead time.

On the other hand, CNC machining has some limitations, which include:

• It&#;s not suitable for large-scale production.
• CNC machines are more expensive than manually operated machines, which leads to an increase in the cost of production.

Method #2: Aluminum Die casting

Die casting is another ancient manufacturing method suitable for making aluminum and other metal prototypes. This process works by pouring the liquid aluminum into a mold, which takes the inverse shape of the desired prototype. While effective, die casting is expensive because it requires special tools and is labor-intensive.

The benefits of using die casting to make an aluminum prototype include:

• It provides an excellent surface finish with precise dimensional tolerances.
• Reduced wastage of materials compared to CNC machining.
• Produces a very strong part.

Its limitations include the following:

• This process requires special tooling, which is expensive.
• You need to have the technical knowledge to achieve the required results.
• It consumes a lot of time.

Method #3: Sheet Metal Prototyping

Sheet metal prototyping is like CNC prototyping but more suitable for working with sheets of aluminum materials. It comprises different processes, hence, most manufacturers to it as a set of techniques such as cutting, pressing, deformation, and pinching used in shaping a metal part to the required shape and form.

Benefits of sheet metal prototyping include:

• You can get multiple similar copies of prototypes simultaneously.
• Uses a set of fabrication techniques.
• Highly consistent.

Its limitations include the following:

• It&#;s an expensive process.
• It doesn&#;t accommodate complex designs.
• Turnaround time is high.

Method #4: Aluminum Extrusion

This aluminum prototyping process combines the characteristics of both 3D printing and casting. Aluminum extrusion forces aluminum alloys through open molds to create an elongated part and is suitable for manufacturing components like metal bars, joints, and brackets.

Benefits of aluminum extrusion include:

• Lower material use.
• There is lower wastage of materials due to recyclability.
• It produces strong aluminum prototypes that, in terms of their properties, look like those of metal casting.

Limitations of aluminum extrusion include:

• It requires expensive, special tools.
• Only compatible with a limited range of aluminum alloys.
• Mostly suitable for producing elongated parts.
• It is time-consuming.

Method #5: 3D Printing

3D printing is an additive manufacturing process suitable for creating an aluminum prototype when looking for reduced waste, flexibility, suitability for complex design, etc. It comprises several techniques, with DMLS (Direct Metal Laser Sintering) technology being the more common method for creating 3D-printed aluminum parts.

The DMLS process involves using a high-powered laser beam to sinter granules of aluminum alloys in a layer to form the required part. Like the CNC machining method, 3D printing also requires 3D CAD models to make aluminum prototypes precisely. However, it is more suitable for producing parts with difficult geometries.

Below is a list of the benefits of 3D printing:

It can be used to create prototypes with complex designs. Suitable for manufacturing small batches of projects.

Limitations of 3D printing include:

• Producing aluminum prototypes with 3D printing is more expensive than CNC machining.
• Some physical and chemical properties of the parts produced don&#;t show.
• It requires extra surface treatments.

How To Choose The Right Aluminum Prototyping Method?

Selecting the most suitable aluminum prototyping method is crucial to avoid material waste or poor results. Some factors must be considered before selecting an aluminum prototyping method. They are:

1. Quality of the Material

The choice of an aluminum prototyping method strongly depends on the type of aluminum alloy to be used. This also plays a huge role in the quality of the prototype. As a result, you should ensure you know about the properties of the aluminum alloy you are dealing with. A way of knowing the right material quality is by research. A faster way would be by talking to aluminum CNC prototype manufacturers to choose the right material.

2. Prototype Quantity

The number of aluminum prototypes needed is also essential in selecting the type of process. Manufacturing methods like CNC machining and 3D printing will be more suitable for producing a small batch of materials. However, die-casting methods are suitable for producing up to 10,000 aluminum prototypes.

3. Complexity

Selecting the right aluminum prototyping method also depends on the complexity of the intended and prototype details. 3D printing and CNC machining are suitable for making a complex prototype against methods such as sheet metal prototyping.

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4. Cost

Cost plays an important role when choosing the right aluminum prototyping process. It depends on several factors such as material cost, labor cost, and the need for mass production. For mass-produced aluminum prototypes, die casting could be the better method. However, for other processes, you can talk to the prototyping services about getting the right operational cost relating to capital, time, and labor to make the aluminum prototype.

Benefits of Aluminum Prototypes

Based on type, properties, functions, and required strength, various materials are suitable for manufacturing prototypes. However, aluminum is the most common due to its excellent mechanical properties. Below are some of the advantages of picking aluminum prototypes:

1. Excellent Functional Performance

Although the functional performance of the aluminum prototype depends on the aluminum prototyping method, these prototypes are highly functional or mechanical effects. This is due to the high machinability of aluminum. Nevertheless, a functional prototype will require an aluminum alloy with high strength and quality.

2. High Thermal Resistance

Compared to less expensive alternatives like plastics, the aluminum prototype can resist high temperatures well. As a result, the material can be subjected to high temperatures to test for its use in extreme conditions.

3. Nice Aesthetics

Either with CNC machining or 3D printing, aluminum prototypes provide better aesthetics. Even as non-functional prototypes, they still look very attractive.

4. Cost-effective

Unlike plastics, aluminum prototypes are more cost-effective. This is due to the physical characteristics of aluminum, which decrease the rate of part substitution, eventually leading to reduced manufacturing costs.

5. High Accuracy

Aluminum has high machinability. Hence, aluminum prototypes obtained through additive and subtractive processes have tight tolerance. As a result, using them can ensure you have a real part with excellent quality after adequate testing.

Applications of Aluminum Prototypes

Aluminum is a metal with applications in various industrial sectors. The following are some of the areas where aluminum prototypes are commonly used.

1. Medical Field

In this sector, neatness, and biocompatibility are crucial to prevent bacteria and other microorganisms from causing harm. However, aluminum prototypes and parts are up to producing clean and biocompatible medical instruments. Also, it is suitable for producing real parts such as orthopedic and surgical tools and general-purpose facilities such as trays and containers.

2. Aircraft Industry

Aluminum fits this description of lightweight with great strength perfectly. As a result, it makes it a suitable material in the aerospace field, especially in testing real parts. Its high corrosion resistance protects the aircraft from severe damage when exposed to extreme environmental conditions.

3. Automobile Industry

Aluminum car parts such as engine radiators, engine cylinder blocks, wheels, and transmission bodies should be durable, lightweight, and compatible with their environment. As a result, aluminum is a material that automotive parts manufacturers use to accomplish these goals. Also, aluminum is suitable for making recyclable real car parts which helps improve the sustainability of vehicle parts using aluminum prototypes.

How Flagship Can Help You with Aluminum Prototyping?

Aluminum prototyping is making a prototype of parts and components in several industries, especially automotive prototyping. There are several processes to make an aluminum prototype, and choosing the right one most often requires a field professional&#;s services.

Flagship is an experienced aluminum prototyping manufacturer with vast aluminum and prototyping knowledge. We have a team of experts that can help you bring your ideas from an initial stage to production quickly. Just upload your CAD files and let&#;s start a new project!

Conclusion

The aluminum prototype is very important in manufacturing processes because it helps test parts to measure how the real part would function by giving a visual exhibition of what the final product will look like and its functionalities. This article talks about the different aluminum prototyping methods and how to select the right method for creating an aluminum prototype.

FAQs

What&#;s the cost of producing aluminum prototypes?

The total cost of aluminum prototyping depends on various factors, like the type of aluminum alloy used, the volume of prototypes to be manufactured, etc.

Which aluminum alloy is best suited for prototyping?

Aluminum is the most widely used alloy for prototyping. Apart from being easy to work with during machining, it also exhibits good mechanical properties such as high strength, good corrosion resistance, and excellent weldability.

Melted plastic is shaped and formed into the profile of the exit die opening. At this stage, the extrusion is still hot and malleable. The material passes through a cooling bath filled with water which uniformly cools and solidifies the extrusion, helping bring it to its final shape. Air or metal contact cooling systems are also sometimes used. A vacuum sizing stage before the cooling stage may be necessary for extrusions that contain hollow features to mitigate defects and maintain shape. Pull rollers apply a uniform pulling pressure which helps smooth the plastic and move it further down the line. The plastic extrusion receives quality control checks using onboard laser measurement systems, and good sections are then spooled or cut to final part dimensions. The product is then ready for final quality checks, storage, and packaging.

The plastic extrusion process typically involves seven steps:

1. Material Preparation

Raw plastic, usually in the form of pellets or granules, is prepared for the extrusion process. You choose a material based on what properties you expect in the final product. Some plastics emphasize strength, flexibility, color, or other properties. Raw plastic material is typically stored in a hopper. It is introduced into the extruder through the feeding opening at the rear end of the barrel. As the plastic pellets descend into the barrel and contact the screw, they also begin to melt. 

2. Melting and Mixing

The plastic material is introduced into an extruder, a machine comprising a heated barrel and a rotating screw. The screw within its barrel rotates in a controlled manner but can operate at speeds as high as 120 rpm. As the screw rotates, it advances the plastic beads within the barrel, subjecting them to heat generated by the barrel itself. This heat, combined with the friction induced by the screw's movement, causes the plastic material to melt. Most extrudable plastics melt at around 200 to 275 °C. 

Upon leaving the screw, the molten plastic passes through a screen pack designed to eliminate contaminants. To withstand pressures that can surpass 34 MPa, a breaker plate reinforces the screens. 

3. Extrusion Process

Following the thorough mixing and uniform melting facilitated by the extruder, the molten plastic is pushed through a specially designed die or mold located at the extruder's end. This will give the plastic its final dimensions.

4. Cooling and Sizing

As the plastic material exits the die, it enters a cooling zone. Air- or water-cooling systems often assist during this stage. This removal of heat solidifies the plastic into its final shape. Additionally, sizing tools or equipment may be used to ensure it meets the required dimensions.

5. Hauling and Cutting

The extruded plastic material is pulled or "hauled" through the process using rollers or other mechanisms. This keeps the extrusion moving at the proper speed and tension. After hauling, the continuous extruded profile is cut into specific lengths using cutting tools or saws.

6. Additional Processing

Some extruded items need additional processing. This could include: surface treatments, printing, markings, or attaching other components to the extruded profile.

7. Inspection and Quality Control

The extruded plastic profiles are inspected for defects, dimensional accuracy, and other quality criteria. Any profiles that do not meet the required standards may be rejected or sent for further processing.

A plastic extrusion process&#; timeline depends on several factors, including: the complexity of the product, the type of plastic being extruded, the speed of the extrusion line, and the manufacturer&#;s specific requirements. Generally, plastic extrusion is known for its efficiency and the speed with which it can produce high volumes of continuous products.

Simple products with basic shapes, such as straight pipes or profiles, can be extruded relatively quickly. However, more complex products that require intricate profiles, multiple layers, or additional post-extrusion modifications might take longer.

Materials That Can Be Used in Plastic Extrusion

Plastic extrusion is a versatile manufacturing process that can be applied to a wide range of materials. Here's a list of some common materials that can be extruded this way: 

1. Polyethylene (PE)

Polyethylene is a thermoplastic known for its flexibility, durability, and chemical resistance. It strikes a good balance between colorability, strength, and low-temperature performance. It's used in packaging films, pipes, and containers, among many other things.

2. Polypropylene (PP)

Polypropylene is another versatile thermoplastic that strongly resists chemical agents. This polymer achieves a perfect equilibrium between strength, impact resistance, color versatility, and performance in low-temperature conditions. It's used in packaging, automotive parts, textiles, and more.

3. Polyvinyl Chloride (PVC)

Polyvinyl chloride is a common thermoplastic known for its versatility, durability, and cost-effectiveness. It's used in pipes, cable insulation, and flooring. There are two distinct types: rigid PVC and flexible PVC. Flexible PVC is renowned for its affordability and adaptability. This material strikes an excellent middle ground between resistance to weather conditions, tear resilience, and tensile strength. Rigid PVC, on the other hand, resists impacts and remains stable under ultraviolet radiation. It finds use in applications such as pipe construction, refrigeration units, windows, and doors. Its inherent rigidity positions it as a feasible alternative to wood and metal across a lot of applications.

4. Polystyrene (PS)

Polystyrene is a lightweight and rigid thermoplastic commonly used in packaging materials, disposable utensils, and insulation.

5. Acrylonitrile Butadiene Styrene (ABS)

ABS is manufactured through the polymerization of styrene and acrylonitrile, with the presence of polybutadiene improving its toughness compared to pure polystyrene. The styrene element in acrylonitrile butadiene styrene gives it a glossy, waterproof surface. Polybutadiene, meanwhile, enhances its durability regardless of temperature variations. ABS is a tough and impact-resistant thermoplastic that&#;s ideal for both strength and aesthetics, such as in automotive parts, toys, and consumer electronics.

6. Polyamide (PA or Nylon)

Nylon is a strong and durable thermoplastic with excellent mechanical properties. It's used almost everywhere, including in automotive parts, industrial components, and textiles.

7. Polycarbonate (PC)

Polycarbonate is a transparent thermoplastic known for its impact resistance and optical clarity. This substance offers a well-rounded combination of attributes, encompassing rigidity, resistance to abrasion, color adaptability, and good performance across both high and low temperatures. It's regularly seen in automotive components and electronic enclosures.

8. Polyethylene Terephthalate (PET)

Polyethylene terephthalate ends up in packaging materials, especially for beverages and food products. It's also used in fibers for textiles and engineering applications.

These are just a few of the many materials that can be processed through plastic extrusion. Other polymer extrusion materials include thermoplastic vulcanizate (TPV), thermoplastic alloy (TPA), styrene, mineral-filled polypropylene, acrylic, and chlorinated polyvinyl chloride (CPC). 

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