Metallic prototypes for the pressure die casting industry

Abstract

Very useful engineering models for product development can be rapidly available using Rapid Prototyping technologies. A diversity of industrial sectors can benefit from the use of these technologies, through speed improvement in the product development phase and consequently minimising the time to market. Rapid Prototyping technologies also allow the direct or indirect production of metallic prototypes to be used in the development of fully or semifunctional products, like house ware, kitchen and bathroom taps, sand castings, die castings and components to be produced by pressure die casting for the automotive industry. It is the aim of this work to describe a 3 years experience in the development of metallic conversion techniques, to supply functional metallic prototypes for different national companies. The advantages and the disadvantages of some possible complementary technologies to obtain functional prototypes of products that will be produced by pressure die casting are presented. The "lost model" technique using LOM, Thermoject, SLA "Quick Cast", and the "lost wax" will be compared in terms of accuracy, speed and costs, with techniques that use silicone and the resin filled moulds, considering the production of pre-series of 3 to 50 prototypes.