What are the prototyping options with a design intended for die cast production?
A. Beyond 3D computer product modeling, there is a wide range of prototyping options for eventual die casting. They include prototype parts produced by conventional machining from stock of the same alloy family; by CNC machining directly from CAD files; by one of several of the new rapid prototyping (RP) techniques now including Fused Deposition Modeling (FDM); and by creating an RP or conventionally modeled master for plaster molded or investment cast prototypes. Gravity cast prototypes are sometimes used. Since only production from an actual die casting die can yield a part with precise die cast characteristics, a single-cavity prototype die is the most thorough approach to critical product performance evaluation, although the alternative requiring the greatest prototype investment and lead time. Today’s most widely accepted prototyping for metal parts, CNC machining, and newest RP prototyping process, FDM, are discussed below. The limitations and prerequisites for using various prot
