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How to choose the right way for aluminum profile manufacturing

Aluminum is the most commonly used material in prototyping. Industries such as the aerospace, medical and automotive industries require durable mechanical and structural components. Aluminum prototypes are strong, have excellent welding capabilities, and are corrosion resistant, making them essential in manufacturing operations.

Manufacturers use different techniques to create aluminum prototypes. Depending on the part, quantity or geometry, they can choose to use 3D printing, CNC machining, aluminum casting services. Each of these methods has its advantages and disadvantages. A wrong choice can result in high tooling and manufacturing costs, non-functional and unusable parts.

This article introduces the commonly used aluminum prototyping methods, hoping to better help you understand which method is best for your prototyping project.

What is aluminum alloy processing?

Rapid manufacturing process from aluminum blocks. The process involves different techniques and different machines to come up with the best design.

Manufacturers and designers try to launch their final products in the shortest possible time. This is done to save time and cost. Therefore, a sample that is very close to the original product was made.

Aluminum products are in great demand and have many applications in different industries. Aluminum prototype makers build prototypes that help refine designs before producing high-budget products.

Aluminum Prototypes in Different Forms

Method 1: CNC machining

Custom machining from design files is one of the most common machining methods used to create aluminum prototypes. This machining process relies on computer input to precisely control the machining tool to remove the portion of the aluminum workpiece and leave the desired portion. In addition, as a subtractive manufacturing method, it leads to material waste. But what makes CNC machining unique, and when should you use it?

CNC machining offers good quality, excellent surface finish, repeatability, and compatibility with a wide variety of aluminum alloys. more importantly? Since the CNC machining process begins with the creation of a 3DCAD model, you can quickly change designs between prototypes without impacting lead times.

CNC machining is especially useful for testing and producing prototypes. With 4-axis and 5-axis CNC milling machines, you can create complex prototypes that are difficult to handle with other machining methods.

Method 2: 3D printing

3D printing is another popular way of creating aluminum prototypes, which uses additive manufacturing techniques to reduce waste. Direct metal laser sintering (DMLS) technology can be used to create 3D printed aluminum prototypes. Here, aluminum powder particles are sintered layer by layer using a high-power laser to form the desired shape.

Like the CNC machining process, 3D printing relies on 3D, CAD models to accurately create aluminum prototypes. Its minimum feature size ranges from 0.25 mm to 0.8 mm, allowing the fabrication of complex geometries with complex internal cross-sections. However, 3D printed aluminum prototypes are not cheap and often require additional surface treatments.

3D printing to create aluminum prototypes is usually more expensive than CNC machining. Therefore, 3D printing is more suitable for manufacturing small parts, especially test versions and production prototypes.

Method 3: Investment Casting

Investment casting, also known as investment casting, is a centuries-old casting process used to create aluminum prototypes. Here, aluminum parts are made by pouring molten aluminum into molds made from wax patterns. The process of making molds is expensive since it requires specialized equipment. Therefore, it is not economically feasible to make a mold for one or two prototypes and is more suitable for mass production.

Investment casting offers excellent surface finish, tight dimensional tolerances, and compatibility with a wide variety of aluminum alloys. Additionally, investment casting has less material waste than CNC machining. The only downside to this process is its size limitation. If you're building bulky aluminum parts, this probably isn't the best choice for you.

Advantages of Aluminum Prototyping

Depending on the part, its function and strength requirements, different materials can be used for prototyping. However, aluminum is preferred for both aesthetic and functional reasons. Here are some benefits of choosing an aluminum prototype.

Excellent functional performance

While some archetypes have no mechanical or functional effect, others must be used. Pre-production, hybrid and functional prototypes can all work; therefore, good quality and strength are required. Aluminum is the metal of choice due to its excellent properties.

Higher heat resistance

If you compare it to cheaper options like plastic, the aluminum prototype is more resistant to extreme temperatures. Therefore, it is not easy to degrade during the production process.

Better aesthetics

Whether you use 3D printing or CNC machining techniques, metal prototypes look better. Furthermore, even as non-functional prototypes, they are more attractive than plastic parts.

Cost-effective

Aluminum prototypes and parts made of metal are much less expensive than plastic parts. This is because the physical properties of the metal reduce the frequency of parts replacement. In the long run, this will reduce production costs.

Test accuracy

The prototypes produced by CNC machining and other processes have high precision. In addition, the aluminum alloys are of such high quality that the parts tested on the market can be produced.

More suitable for mass production

Once the engineers have made the aluminum prototype, the customer can use it for production. It's easier to turn a metal prototype into a finished product. However, if the prototype is made of plastic, it cannot be converted to metal in series production.

High strength

Aluminum alloy has high strength, good corrosion resistance and good plasticity. Due to these excellent properties, they are widely used in most industries. For example, in the aviation industry, aluminum parts are widely used. Thanks to this advantage, customers can be assured of high-quality parts and prototypes.

Summary

Rapid prototyping is not done in ideal form. They need to be processed and finished to get the right end result. China's one-stop shop for all these services from design to surface treatment technology. The generated prototype goes through CNC milling, CNC turning, polishing, anodizing and other processes to achieve a perfect prototype.