Die casting techniques and strategies evolved over time with the introduction of new alloys and expansion into many industries. Along with the high pressure die casting methods, there are many other techniques utilized in the prototyping process of die-casting. Some of the die casting prototyping methods used currently is described below.
Single Cavity Prototype Die
The single cavity prototype die process is the ideal choice when extensive testing of the materials is required. This process has its own unique advantage, as it allows to meticulous evaluation of vital characteristics of the end product and the finish on its exposed surface.
This method also offers other benefits of preventing any costly alterations, by allowing changes in the design of the prototype after producing the initial parts. Furthermore, the time involved in creating the final dies is less in single cavity prototyping than other strategies. However, the single cavity die process is unsuitable for any quicker production process due to the cost and the time involved in the creation of dies.
Gravity Casting
Gravity casting is a less expensive process than the single cavity prototype dies, and therefore, it is the preferred choice in the creation of die cast prototypes. It also requires significantly a lesser amount of lead time than the former process.
The various strategies such as investment casting and plaster molding casting are included in the gravity casting process. There is however many disadvantages that needs consideration before using such die casing prototyping strategy.
The lesser porosity of gravity casting results in increased fatigue strength than normal die-casting. The inability to construct very thin wall width is also impossible using gravity casting.
Rapid Prototyping
Also referred to as the steel process, this technique is linked with various other processes like, stereo lithography, laser sintering, and fused deposition modeling. Rapid prototyping is preferred for the production of huge number of units while the dies are being fabricated.
Rapid prototyping allows for a thorough and accurate analysis of the product before creating the dies. This is because the alloys along with the physical and thermal properties employed in rapid prototyping are the same as the production run.
Plaster Mold Prototyping
Plaster mold casting, also known as rubber plastic mold casting, works with many alloys like Aluminum, Magnesium, Zinc, and ZA. The advantages of this prototyping process are that it enables making changes to the geometry of the parts quickly. The process is ideal for producing large number of prototypes and the most economical among all other prototyping process.