Rapid, Wax-Die & Metal Prototyping for Investment Casting
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Prototyping
A vital part of investment casting, prototyping enables the review and analysis of a designed part before commencing full-scale casting production. It helps reduce costs by eliminating the risk of imperfect designs entering production and allows customers to test Design for Manufacture (DFM) suggestions to minimise component costs.
Texmo Blank offers industry-leading prototyping timescales using innovative technology. The fastest method uses 3D printing to create accurate physical prototypes from digital designs sent by clients.
Rapid Prototyping
This service uses 3D printing to produce intricate wax or plastic models of castings. These models are then used to create ceramic moulds for metal investment casting. The process steps are identical to those used in hard tooling, and destructive testing of metal castings produced from rapid prototyping wax confirms the same mechanical properties as serial production parts. Rapid prototyping eliminates the need for tooling before final design approval, significantly reducing both time and cost.
Wax Die Prototyping
This method takes longer as it requires an aluminium tool for wax injection. Wax is injected into the tool to create a prototype pattern used to make the metal casting mould. This tooling is simpler compared to production tooling, but it is more expensive and less suitable for low-volume prototyping. It's cost-effective for larger-scale prototyping, but eventually, production tooling is needed once the designs are finalised.
Metal Prototyping
For a faster solution, Texmo Blank can machine prototypes from wrought materials or print parts via laser sintering of powder metals. However, these parts differ structurally from castings and thus do not accurately represent the mechanical properties of castings.
Choosing a Prototype Type
- Rapid prototyping is recommended for small quantities to quickly review feasibility, fit, and function without the need for tooling.
- Wax die prototyping is suitable for larger-scale prototyping, but it is costlier and slower due to the need for tooling.
- The best choice depends on the customer's needs; the sales team can assist in making a decision.
FAQs
What is prototyping?
It's the physical realisation of a design for testing and review before full production, enabling troubleshooting and refinement.
How long does prototyping take?
3D-printed wax castings can be supplied within 7-14 working days. Wax die prototypes typically take 21 to 28 days to complete. Additional machining or processes might add time.
Is prototyping right for me?
If a design is new and needs fit and function testing, prototyping is advised. Fixed and proven designs should go directly to production tooling for efficiency.
How long does investment casting prototyping typically take?
The duration of investment casting prototyping varies depending on the method chosen. Rapid prototyping using 3D-printed waxes typically takes between 7 and 14 working days. Wax die prototyping, which requires creating aluminium tooling, usually takes longer, around 21 to 28 working days. Additional processes, such as machining or finishing, may add a few days to the timeline.
How many prototype parts can be produced with rapid prototyping?
Rapid prototyping is ideal for producing smaller quantities, typically ranging from a handful to several dozen parts. Because it does not require tooling, it allows for quick iterations and is suited for feasibility studies, fit, and function testing before committing to production tooling.
Is prototyping cost-effective compared to production tooling?
Prototyping, especially rapid prototyping, is cost-effective for initial design validation, as it avoids the upfront investment in tooling. However, as volumes increase and the design becomes finalised, transitioning to wax die tooling for production makes greater economic sense due to lower per-part costs over large runs.
What are the benefits of rapid prototyping versus wax die prototyping?
Rapid prototyping offers faster turnarounds and flexibility, allowing for the testing of multiple design iterations without incurring tooling costs. Conversely, wax die prototyping produces prototypes that are more representative of final production parts; however, it requires tooling and incurs higher costs and longer lead times.
Can prototyping help reduce overall production costs?
Yes, prototyping helps identify design issues early and optimises manufacturability, which can reduce costly revisions during production. It also helps fine-tune process variables to improve yield and part quality.
Does Texmo Blank support metal prototyping without casting?
Yes, we offer metal prototyping options, including machining from wrought materials and laser sintering of metal powders. Note that these parts will have different microstructures and properties compared to cast parts and may not be suitable for mechanical testing simulating final castings.
Get In Touch
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If that sounds like an investment castings partner you’d like to work with, you can book an introduction call with our friendly and knowledgeable New Relations Team — in a language and time zone to suit you.