Metal die casting prototype parts are the backbone of product development—they let teams test designs, подтвердить функциональность, and iterate fast before mass production. But with so many material options (алюминий, магний, цинк), casting processes (HPDC, vacuum-assisted), and design rules to follow, Легко чувствовать себя подавленным. How to choose the right approach for your prototype? This guide breaks down everything from material selection to testing, with practical tips to create high-quality, cost-effective metal die casting prototypes.
1. Rapid Die-Casting Prototyping: Get Samples Fast Without Sacrificing Quality
В разработке продукта, speed matters.Rapid die casting prototype solutions cut lead times to get you testing sooner—critical for staying ahead of competitors.
Key Rapid Prototyping Options
| Решение | Время выполнения | Идеально подходит для | Пример использования |
|---|---|---|---|
| Quick-turn casting parts | 3–5 дней | Простые прототипы (НАПРИМЕР., Основные корпусы) | A startup needing to test a new electronic device’s shell |
| Fast metal prototype casting | 5–7 дней | Parts with moderate complexity (НАПРИМЕР., скобки) | An automotive supplier validating a new sensor mount |
| 24-hour casting samples | <1 день | Emergency fixes or urgent design checks | A manufacturer needing to replace a broken prototype part for a client meeting |
| Express aluminum prototype | 2–4 дня | Алюминиевые части (the most common prototype material) | A consumer goods brand testing a new kitchen tool’s handle |
The secret to rapid prototyping? Prioritize “good enough” for initial tests. Например, if you’re just checking fit (not cosmetic finish), skip expensive anodizing—focus on getting the part in hand to validate dimensions.
2. Aluminum Die-Cast Prototypes: The Go-To for Balance of Strength & Расходы
Aluminum is the most popular material for die casting prototypes—it’s lightweight, сильный, и доступно.Aluminum prototype casting works for nearly every industry, from electronics to automotive.
Top Aluminum Alloys for Prototypes
| Сплав | Ключевые свойства | Ideal Prototype Use |
|---|---|---|
| ADC12 prototype parts | Бюджетный, Отличная литья, Гладкая поверхность отделка | Косметические части (НАПРИМЕР., Телефонные чехлы, Дистанционное управление) |
| A380 aluminum prototype | Высокая сила, Хорошая механизм, теплостойкость | Структурные части (НАПРИМЕР., двигатели кронштейны, power tool housings) |
Why choose aluminum? Аlightweight AL casting sample weighs 30–50% less than steel, making it perfect for portable devices or automotive parts where weight matters. Плюс, aluminum rapid casting is fast—most suppliers can deliver parts in 3–7 days.
3. Magnesium Die-Cast Prototypes: The Lightest Option for High-Performance
If weight is your top priority (НАПРИМЕР., aerospace or high-end electronics), magnesium prototype casting это путь. Магний есть 33% lighter than aluminum—ideal for parts where every gram counts.
Key Magnesium Alloy for Prototypes
- AZ91D prototype parts: The most common magnesium alloy for die casting. It has good strength and castability, сделать его идеальным для:
- Light Mg casting sample (НАПРИМЕР., Кадры ноутбука, drone bodies)
- Thin-wall Mg casting (вплоть до 0.5 mm—great for slim devices like tablets)
Magnesium prototypes do have tradeoffs: they’re more expensive than aluminum, and they corrode easily (so you’ll need a protective coating like chemical conversion). But for high-performance products, the weight savings are worth it.
4. Zinc Die-Cast Prototypes: Perfect for Small, Подробные части
Zinc prototype casting shines for small, intricate parts—zinc flows easily into tight spaces, making it ideal for prototypes with fine details (НАПРИМЕР., передачи, аппаратное обеспечение).
Top Zinc Alloys for Prototypes
| Сплав | Ключевые свойства | Ideal Prototype Use |
|---|---|---|
| Нагрузки 3 прототип деталей | Низкая температура плавления, Хорошая точность размеров | Маленький, точные детали (НАПРИМЕР., смотреть компоненты, разъемы) |
| Нагрузки 5 casting sample | Higher strength than ZAMAK 3 | Parts needing durability (НАПРИМЕР., Дверные ручки, Небольшие шестерни) |
Zinc’s benefits:
- Miniature zinc prototype: Can cast parts as small as 5 мм × 5 mm with sharp details.
- Zinc rapid casting: Быстрое охлаждение (zinc solidifies quickly) means shorter cycle times—suppliers can make small batches in 2–4 days.
5. Кастинг с высоким давлением (HPDC) Прототипы: For Production-Ready Parts
Кастинг с высоким давлением (HPDC) прототипы use the same process as mass production—making them perfect for validating how parts will perform in full-scale manufacturing.
Key HPDC Prototype Features
- HPDC prototype parts: Made with high pressure (100–150 МПа) to ensure dense, Сильные части.
- Thin-wall HPDC casting: Can produce walls as thin as 0.4 мм (ideal for lightweight parts like smartphone frames).
- Multi-slide HPDC prototype: Uses multiple slides to cast complex shapes (НАПРИМЕР., детали с подрезок) without extra machining.
When to choose HPDC? If you’re close to mass production and want a prototype that matches the final product’s properties. АHPDC aluminum prototype, например, will have the same strength and surface finish as production parts.
6. Vacuum-Assisted Die Casting Prototypes: For Low-Porosity Parts
Пористость (tiny air bubbles) is a common issue in die casting—especially for parts that need to hold fluids (НАПРИМЕР., насос) or withstand high pressure.Vacuum die casting prototype solves this by removing air from the mold before casting.
Benefits of Vacuum-Assisted Prototypes
- Reduced-porosity casting: Cuts porosity by 70–80% compared to standard die casting.
- High-integrity vac casting: Ideal for parts like hydraulic components or medical devices where strength and leak resistance matter.
- Vac-cast aluminum parts: The most common vacuum-assisted prototype—aluminum’s fluidity pairs well with vacuum to fill thin walls and complex shapes.
7. Thin-Wall & Micro Die-Cast Prototypes: For Slim, Tiny Parts
Modern products are getting slimmer and smaller—so prototypes need to keep up.Thin-wall casting prototype иmicro die casting parts let you test designs for the latest devices.
Key Capabilities
| Тип | Минимальная толщина стенки | Идеальный вариант использования |
|---|---|---|
| Thin-wall casting prototype | 0.3 мм (aluminum/magnesium) | Slim devices (НАПРИМЕР., wireless earbud cases, Умные часы групп) |
| Micro die casting parts | 0.2 мм (цинк) | Tiny components (НАПРИМЕР., microchip connectors, медицинские иглы) |
| Ultra-thin aluminum prototype | 0.3 мм | Легкий вес, slim parts (НАПРИМЕР., tablet back covers) |
| Mini zinc die casting | 0.2 мм | Маленький, подробные части (НАПРИМЕР., Ювелирные изделия застежки, micro-gears) |
Кончик: For thin walls, use vacuum-assisted casting (to ensure full filling) and conformal cooling (to prevent warpage).
8. Пост-махинация & Finishing for Cast Prototypes: Make Parts Look and Work Like Final Products
Casting alone rarely gives you a finished prototype—пост-махинация & отделка are key to getting parts ready for testing or client presentations.
Обычные шаги после обработки
| Шаг | Цель | Идеально подходит для |
|---|---|---|
| CNC machining casting prototype | Adds precision features (НАПРИМЕР., отверстия, нить) that can’t be cast | Parts needing tight tolerances (НАПРИМЕР., датчики) |
| Trim & drill die casting | Removes excess metal (вспышка) and adds simple holes | Basic prototypes where fit is more important than finish |
| Anodized casting sample | Добавляет защитный, Цветный слой (Type II for cosmetic, Type III for wear) | Aluminum prototypes (НАПРИМЕР., потребительские товары, Автомобильная отделка) |
| Powder-coat prototype parts | Добавляет долгосрочный, матовая отделка (available in any color) | Parts needing corrosion resistance (НАПРИМЕР., открытое оборудование) |
| Vibratory finish casting | Smooths edges and removes small burrs | Небольшие части (НАПРИМЕР., zinc hardware, magnesium brackets) |
Для чаевого: For rapid prototypes, skip unnecessary steps. If you’re just testing functionality, подрезать & drill may be enough—save anodizing for final presentations.
9. Размерный & Mechanical Testing of Cast Prototypes: Prove Parts Meet Specs
You can’t trust a prototype until you test it.Размерный & mechanical testing ensures your parts meet design goals and will perform in real use.
Key Tests for Cast Prototypes
| Тест | Цель | Что искать |
|---|---|---|
| CT scan casting inspection | Finds hidden defects (НАПРИМЕР., пористость, трещины) | Total porosity <1% (Для структурных частей) |
| X-ray die casting check | Обнаруживает внутренние недостатки (simpler than CT for basic checks) | No large pores (>0.5 мм) in critical areas |
| CMM prototype measurement | Verifies dimensions (НАПРИМЕР., Диаметр отверстия, Часть длины) | Dimensions within ±0.05 mm of design specs |
| Tensile test casting bar | Измеряет силу (how much force the part can take before breaking) | Tensile strength ≥80% of the final production part |
| Porosity analysis report | Documents the amount and location of porosity | No porosity in high-stress areas (НАПРИМЕР., отверстия для болтов) |
Prioritize tests based on your prototype’s use. Например, a magnesium drone frame needs a tensile test and CT scan (to check for weak spots), while a zinc jewelry clasp just needs a CMM check (to ensure it fits).
10. Низкий объем & Bridge-Tooling Strategies: From Prototype to Production
Once your prototype is validated, you may need small batches (10–500 деталей) before mass production.Low-volume die casting иbridge tooling casting fill this gap.
Key Strategies
- Soft-tool casting prototype: Uses low-cost tools (НАПРИМЕР., алюминиевые формы) for small batches—cheaper than production tooling and fast to make (1–2 недели).
- Insert die casting mold: Swaps inserts in a standard mold base to make different parts—ideal if you need multiple prototype variants (НАПРИМЕР., 3 different lid designs).
- Quick-change casting inserts: Changes inserts in 30 minutes or less—cuts setup time for low-volume runs.
Bridge tooling is perfect for:
- Testing market demand (make 100 parts to sell and get feedback)
- Filling gaps between prototype and mass production (if production tooling is delayed)
11. Design for Die Casting (DfDC) Guidelines: Avoid Common Prototype Mistakes
Bad design leads to bad prototypes—Design for Die Casting (DfDC) Руководящие принципы help you create parts that cast easily and perform well.
Top DfDC Rules for Prototypes
- Draft angle casting design: Add 1–3° of draft to all vertical surfaces. No draft = parts stick in the mold = wasted time and money.
- Fillet radii prototype: Добавить филе (округлые края) to all corners. Sharp corners cause stress cracks and make casting harder.
- Uniform wall casting rule: Keep wall thickness consistent (± 0,2 мм). Thick spots cool slowly and cause shrinkage; thin spots may not fill.
- Undercut avoidance casting: Avoid undercuts (features that hang over and prevent the part from being pulled out of the mold). If you need an undercut, use a slide (but this adds cost to the prototype).
- Ворота & runner optimization: Position gates (где металл попадает в форму) to fill the part evenly. Для небольших прототипов, use a pinpoint gate (small and easy to remove).
Пример: A client once designed an aluminum prototype with 0° draft and sharp corners—every part stuck in the mold, doubling their lead time. Adding 2° draft and fillets fixed the issue.
Yigu Technology’s Perspective on Metal Die Casting Prototype Parts
В Yigu Technology, we tailor metal die casting prototypes to clients’ needs. We offer rapid options (24-hour samples) for urgent tests, and HPDC/vacuum casting for production-ready parts. We guide material choice—aluminum for balance, magnesium for weight, zinc for details—and use DfDC to avoid flaws. Our post-processing and testing ensure prototypes meet specs. This holistic approach delivers fast, high-quality prototypes that speed up product development.
FAQs About Metal Die Casting Prototype Parts
- Когда мне выбрать magnesium prototype casting над aluminum prototype casting?Choose magnesium if weight is critical (НАПРИМЕР., аэрокосмическая, high-end electronics)-его 33% легче алюминия. Pick aluminum for most other cases (better cost, коррозионная стойкость, and availability). Magnesium works best for parts where every gram saves fuel or improves performance.
- В чем разница между HPDC prototype parts and standard die casting prototypes?HPDC использует высокое давление (100–150 МПа) to make dense, strong parts—matching mass production processes. Standard die casting uses lower pressure (50–80 МПа) and is cheaper/faster for initial tests. Use HPDC if you want a prototype that behaves like the final production part.
- How can Design for Die Casting (DfDC) Руководящие принципы save time on prototypes?DfDC rules (НАПРИМЕР., проект углов, uniform walls) prevent common issues like stuck parts or incomplete filling. Например, adding 1–3° draft avoids mold sticking—cutting rework time by 50%. Skipping DfDC often leads to multiple prototype iterations, delaying your project.