Metal Prototype

It is crucial to make every product successful and generate more sales from that product demands the best strategies and planning. One of the most essential steps in creating and launching your product is to make a prototype of that product before it is released to the market. The term “Metal Prototype” applies to using all metallic machinery for the production of a prototype for your device with metals.

These prototypes are generally helpful for the production of military weapons, airplanes, and ships, etc. As these large bodies aren’t going to provide us with more significant details in plastic or glass, so their prototype is made using metals. The other reason for making Metal Prototype is that they are more durable and can be good to attract customers to the actual product.

Figure 1 – Metal Prototypes

1. Why Is a Metal Prototype Better Than a Plastic Prototype?

Whether a prototype is made up of metal or plastic, its simple purpose is to get the idea about the actual product that a manufacturer would expect to create. However, the type of prototype you prepare should be dependent on the type of product you would like to make. If you are planning to prepare larger machinery or a large vehicle, you should definitely create its prototype using metal.

Most of the manufacturers in China prefer to use plastic instead of metal for prototyping. While doing this for the cost reduction is okay, but if a designer wants a prototype that functions as the real one, he should never go for manufacturing a plastic prototype. These materials like plastic can only be used when the functionalities in the prototype aren’t crucial to the designer, and he just wants to prepare a general model of his product.

One of the most incredible things about choosing the Metal Prototype is that by this, you get a clear idea of your product, and metallic machinery can be easily created from metallic prototypes. Accuracy is an important step in the creation of the best prototype. And these metallic prototypes are 80 % more accurate than those nonmetallic.

Secondly, metallic prototypes also attract investors to invest more money in the actual production of the prototype. This causes the production of the best quality product and thus playing a role in the increase of sales of that particular product. Metallic prototypes are also very easy to be transformed into a regular, working product.

2. How Is Rapid Prototyping Used for Production of a Metal Prototype?

Rapid prototyping is a common technique of prototyping a product that works by creating a metallic prototype faster with greater efficiency. In rapid prototyping, there is a 3D printing machine that scans the primary information from the computer-aided designs that a designer had prepared.

Figure 2 – Rapid Prototyping for Metal Pasts Production

After successful scanning, the designs are converted into a 3D product by using various types of chemicals, metals, etc. All of these materials are laid layer by layer in a machine, and the prototype is prepared.

Today, most of the prototypes of larger machinery are prepared through rapid prototyping techniques. This is because rapid prototyping reduces the overall time on prototyping to almost half of the conventional prototyping. This type of metallic prototyping is sometimes also called “layer prototyping,” as they prepare a prototype by creating different layers.

For the creation of Metal Prototype, rapid prototyping techniques are the best ones to create complex machinery simply and faster. One of the most important things about rapid prototyping is that it is effortless to fix any kind of error that comes while creating the prototype of a product.

In Other prototyping techniques, we may fix the errors in plastic prototypes, but in the case of metals, the situation may be challenging. But rapid prototyping can be the best option to choose if a manufacturer wants to create a flawless prototype for his product.

Figure 3 – Metal Rapid Prototypes

3. What Are the Techniques Used in Rapid Prototyping for Creating Metal Prototype?

Although there are a great number of the best and effective techniques used in metal prototyping, the one that is best suitable for making a Metal Prototype is 3D printing. However, we will discuss most of the other techniques too. This will provide you an idea of the best technique in rapid prototyping that you can use for creating a Metal Prototype.

· 3D Printing Technique for Metal Prototyping

If we talk about the best technique in rapid prototyping that can be used for creating a Metal Prototype, that is the 3D printing technique. It is the simplest and cheapest technique in rapid prototyping. The 3d printing works on reading the computer-created design and converting it into a 3D model by arranging metallic and plastic substances layer after layer.

The best thing about 3D printing is that you can create the most complex parts of the machinery by just providing the general design of your CAD software to the printer.

Figure 4 – Metal Prototyping by 3D Printing

In short, the 3D printers are the best to convert designs in digital form to the physical condition of that particular object.

· The Use of Stereo Lithography for Metal Prototyping

Stereolithography is another technique that is used in rapid prototyping. However, this technique isn’t that effective as compared to the 3D printing technique in terms of creating a Metal Prototype. This technique is generally helpful in creating a plastic prototype. But that doesn’t actually mean that we can’t use stereolithography for making Metal prototypes.

We can do so, but we will spend a large amount of money and time on it, as the basic purpose of this technique is not the creation of metallic prototypes.

Stereolithography works by photo-sensitive resins. This resin is focused on a large UV laser, and the design is printed in 3D form, which is the prototype of our product.

This technique is generally considered to be the most basic technique in rapid prototyping. This technique gave rise to the other techniques in rapid prototyping, and still, it is used by many manufacturing firms.

Figure 5 – Metal Prototyping

· The Use of FDM Technique for Metal Prototyping

It is another technique that has been used by manufacturers all over the world for creating prototypes. This technique works similar to the method of 3D printing and generally uses the same principles to work.

This technique works on melting the thermoplastic filament that is present inside the machine. After the filament reaches its boiling point, it continues to convert into a liquid state which in turn can be converted into regular shaped models.

The FDM (Fused deposition modeling) is also useful for the creation of the Metal Prototype. Before converting the filament into a regular model, the FDM machine learns the design prepared using the computer, the same as the 3D printers do. After reading the design, further steps are taken, and the metallic prototypes are created.

4. How Is a Metal Prototype Created Using CNC Machining?

Apart from the rapid prototyping technique, one can also use the CNC machining technique for creating a Metal Prototype for his product. This is a modern method for the creation of the Metal Prototype. In CNC machining, a computer processor reads the CAD design for a prototype prepared by a designer. After successful reading of the CAD, it is converted into larger metallic prototypes with the use of modern technological machinery.

Figure 6 – Metal Prototypes by CNC Machining

If we talk about the other cheapest technique for metal prototyping, apart from 3D printing, CNC machining can be the best suitable for your needs. This technique also allows you to make changes in your design during the machinery is working on converting your CAD into a product.

CNC machining can be used to manufacture prototypes of large and complex parts of different types of machinery at low cost. The main for the so much popularity of CNC machining is that it is a modern technique totally operated from a computer. Like rapid prototyping, CNC machining also helps to produce prototypes that are flawless. It can also fix the flaws in the prototype on the go.

5. What Are the Different Types of CNC Machining That Can Be Used for Metal Prototyping?

The history of CNC machining can be traced to the early 40s when the models were created by using different types of electric motors. But now, due to the extreme level of advancement in technology, CNC machining is controlled using modern computers, and sometimes large mainframe computers are used for controlling the CNC machining for the production of Metal Prototype.

Depending upon their usage, the following are some of the best modern CNC machining technologies that can be used for producing Metal Prototypes.

· CNC Mills Technology

This technology operates by the language G-code. CNC mills are one of the best technological equipment that can be used for generating high-quality Metal Prototypes for new instruments and devices. This technology usually contains mechanical parts that are used for making holes and cutting etc. Some of the best examples of tools in CNC milling are the use of modern drills and cutters.

These tools are fitted in large machinery, which produces the prototypes after the operator gives it a command. The most common principle on which this technology operates is cutting and removing extra parts from the metal sheets and drawing them into metallic prototypes. This method is also used by manufacturers in China.

· The Plasma Cutting Technology

Plasma cutting technology is considered to be one of the most popular and influential technology in CNC machining by China’s suppliers. This technology can help you manufacture prototypes by cutting the metallic sheets with a plasma torch and then shaping them into specific shapes. This technology is not only beneficial for metals but also for other materials like plastic, and glass, etc. For the generation of plasma, electric arcs are used.

Figure 7 – Metal Prototypes

One of the most essential things about plasma technology is that it can be used in large manufacturing machines to cut the metal and transform it into a prototype. According to experts, the plasma torch isn’t that much effective as the plasma cutters in manufacturing machines.

This is because the machines are controlled by a computer which directs the plasma torch fitted inside the machine. The plasma torch caring for each and every angle cut the metal at various places and draw them into a prototype. Due to the high accuracy, the use of plasma cutters in machines is preferred on single plasma torches.

· The Lathes Technology

The lathes technology also operates the same as the CNC mills technology. It also uses the same G-code language as the CNC mills use. In fact, this technology can be called better than the CNC mills. This is due to the reason that it is automatic technology and is highly accurate in the production of highly complex mechanical parts in a metallic prototype.

The lathes technology is best suitable for making that type of metallic prototype that contains rotatory parts, which can be highly complex sometimes. This technology is used to produce mechanical parts that are round and spherical. This technology operates by passing the metal between different machines and machine parts for the preparation of the final prototype according to your design.

6. How to Create a Metal Prototype with Metal Casting Technology?

Metal casting technology is another means for creating the best metallic prototypes according to your designs. This technology uses metal in liquid form to convert it into different shapes and models for metallic prototyping. In comparison to other techniques for creating metallic prototypes, the metal casting technique may cost you more. This is because of the fact that metal casting is a little more laborious as compared to other technologies.

The main thing that causes metal casting to be so costly is that before we create a prototype, we have to make a mold for our prototype. Creating a mold will cause us to spend more extra money on 3D printing etc.

However, if a manufacturer is short of other technologies, he can use the metal casting technique for creating his Metal Prototype. The method of metal casting produces solid and complex and structures for prototypes that are more durable. But as we know, prototypes are just for getting an idea of the actual product and attracting the customers to the product, so creating such a hard Metal Prototype doesn’t show much importance.

Figure 8 – A Metal Prototype

7. How to Create a Metal Prototype Using Metal Extrusion Technology?

Metal extrusion is another technique that can be used to produce prototypes of metal. This technology enables a manufacturer to produce a great number of prototypes. So if you are running a designing company, metal extrusion can be the best option to choose among all the prototyping techniques.

Generally, the manufacturing companies don’t take small prototypes or a lesser number of prototyping projects that are to be done using metal extrusion technology. This is because it takes a lot of time for a metal to be converted into a prototype using this technology. So if you’re creating a Metal Prototype, you can only choose this technology if you have a bunch of designs that need to be prototyped.

In this technology, usually, a machine is used to make a large hole in the long metallic surfaces. This converts the ordinary metal sheets into cylindrical objects, which can later be used for making different parts of the metallic prototype, you are going to make.

8. Why Should You Avoid Metal Extrusion Technology?

The most common thing that causes most people to avoid using metal extrusion technology is that the manufacturing companies don’t prepare prototypes with metal extrusion if they are lesser in number.

Another reason to avoid using this technology is that it cost you a lot of money if you produce a Metal Prototype with this technique. And there are already lots of methods available that can prepare the best prototype in lesser time and lesser money.

9. What Are the Main Purposes for Which Metal Prototypes Can Be Used?

For most of the new technological inventions, the prototypes are prepared using plastic. This is due to the reason for reducing the net cost of the product. By prototyping, we are to get the practical shape of our theory at the least amount of cost.

Figure 9 – Process of Metal Prototyping

We only mean to learn what to expect from the manufacturing firms for the final product. Therefore, Metal Prototypes aren’t necessary to be made if you just want a model for your theory. However, if you have designed a car, or something that is significantly larger, then creating a Metal Prototype means something. The following are some of the products where actually Metal Prototypes work instead of prototypes made up of other materials.

· Cars

If you have designed a new car, you will need a prototype of it before you move towards directly making the car. As in a vehicle, you not only need the model, but you’ll also want to confirm the new functionalities in your vehicle if they work. For this purpose, it is better to make a metallic prototype instead of a nonmetallic one.

· Large machinery

For making a prototype of large machinery, you must have to use a metallic prototype. This is because, in machinery, you will be focusing more on the functionalities instead of the shape and appearance. With any CAD software, create a design with your computer and make a Metal Prototype of it to see how it will work if it was a large machine.

· Defense technologies

If you are going to prepare a new weapon, you should prepare a Metal Prototype of it. Defense technologies require a great amount of hard work to prepare. Designing them would require you to observe and consider each and every angle of the weapon. So for getting the best results, it is important for you to create a Metal Prototype for your design. Modern weapons are prototyped by manufacturers in China to make improvements in them.

1. What Is the General Process of Creating a Metal Prototype?

For the creation of a Metal Prototype, one of the above-mentioned techniques is used like steel casting, CNC machining, etc. However, a metal surface before conversion to a completed prototype goes through the following basic steps.

· The Design Is Tested

Before moving towards creating a prototype, the manufacturers test the design that you provide them. Sometimes the reality can shock you when you come to know that due to the certain existence of a fault, your design resulted in the creation of a poor quality prototype. To avoid this, the design that you prepare is passed through various testing steps.

· Prototyping Costs Are Determined

After your design gets finalized, the net cost of the prototyping is determined. The management team will guide you through the whole process and the total amount of money that you will be required for creating a Metal Prototype. In this step, you will also get the idea of what functionalities will cost how much if it is added to the real product.

Figure 10 – Sheet Metal Forming Methods

· Prototype Is Created

After testing your design and finalizing the cost, the manufacturing companies start to prepare your design. It may take from two days to several weeks to prepare a prototype according to your design.

A new design passes through all these three steps to be transformed into a prototype and later on to the actual product.

11. What Is the Average Cost for Creating a Metal Prototype?

Making a Metal Prototype can be a little costly than other prototypes like glass, and plastic, etc. However, the total amount also depends upon the type of prototyping technique that you chose to use. Other factors that determine the cost of your prototyping include the efforts that manufacturing companies need to put in, the design complexity, and the total amount of time that it will require to get prepared.

The manufacturing companies determine the cost on the basis of different materials that will be used in the prototype. The profit for their services is also added to the net worth of creating a metallic prototype.

Using the 3D printing technology, generally, you will be charged some 30 to 3000 $. If you are creating a complex prototype, you may be charging something between 1500 to 12000 $ for using the 3D technology. There is certain equipment that will require you to add mechanical functionalities to the prototype too. Such prototypes will cost you almost 5000 to 50000 $.

12. How to Use Direct Metal Laser Sintering for Metal Prototyping?

The direct metal laser sintering technique is another technique that can be used to produce prototypes of high quality. This technique is basically the type of Rapid prototyping, and most of the processes are the same as rapid prototyping.  In some cases, the use of direct metal laser sintering techniques can be expensive too.

This is due to the reason that this technology produces high prototypes that cannot be produced with 3D printers or other prototyping techniques. It takes a total of almost 2 to 4 weeks for the manufacturing company after you give them the order to create your Metal Prototype.

Figure 11 – DMLS Materials

In this type of technology, metals are used in powder form, and they are drawn into sheets to make prototypes using laser technology. This technique is widespread in most of the areas of China, which are the most significant manufacturers and suppliers of DMLS technology in the world.

The DMLS technique should only be used when you are going to make Metal Prototypes of highly complex parts of large machinery. For small objects, this technique isn’t recommended because there are already existing methods for metal prototyping that perform your task much faster and on a low budget.

13. What materials are used in the DMLS method for creating Metal Prototype?

The most commonly used materials in the method of DMLS are Nickel, aluminum, copper, stainless steel, tough alloys, cobalt chrome, tungsten, and in some cases, titanium too. The main thing that a manufacturer keeps in mind while preparing Metal Prototype using this method is that every metal that a manufacturer use here should be in powder form so that they may be converted into sheets and ultimately to a Metal Prototype.

14. Why Should You Use the DMLS technology for metal prototyping?

The DMLS technology is popular due to its high accuracy. This technology lets you produce high-quality metallic prototypes with greater accuracy. The following are some of the most important reasons for using the DMLS technology for metal prototyping.

· Least complications

One of the main reasons which make the DMLS method so popular is that this technique isn’t that much complex as most of the prototyping techniques is, except that of 3D printing. The DMLS technology allows the manufacturers to prepare high-quality Metal Prototype.

Figure 12 – DMLS Metal Prototypes

· Easy polishing

The prototypes created using the Direct metal laser sintering can easily be polished. A manufacturer can add a lot of beauty to the prototype that he prepares. This technique can be helpful in attracting customers to your product even before the product is launched in the market.

· Mixture of materials

The Direct Metal laser sintering is the best due to its functionality of creating a mixture type of prototype of various materials. Using this technology, you can create a Metal Prototype and use the other materials, too, along with the metal, for making the final prototype. China’s suppliers make great use of it to manufacture sizeable industrial machinery.