Rapid prototyping services

 Aileg

Rapid prototyping services.

We are the world’s fastest digital manufacturing source for rapid prototypes and
demand production parts. Our automated quoting and manufacturing systems allow 
us to produce commercial-grade plastic, metal, and liquid silicone rubber parts within 
days. A manufacturing partner that helps you accelerate speed to market and 
strategically manage demand volatility across the entire product life cycle.

what is rapid prototyping?

what is rapid prototyping?

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing or "additive layer manufacturing" technology.Rapid prototyping with 3D printing is the quick, easy, cost effective way to turn great ideas into successful products.

what is die casting ?

what is die casting ?

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used..

what is plastic injection molding ?

what is plastic injection molding ?

Plastic injection Molding is a manufacturing process for producing parts by injecting molten material into a mould. Material for the part is fed into a heated barrel, mixed (Using a helical shaped screw), and injected (Forced) into a mould cavity, where it cools and hardens to the configuration of the cavity.Plastic injection Molding is a manufacturing process for producing parts in large volume. It is most typically used in mass-production processes where the same part is being created thousands or even millions of times in succession.

what is die casting ?

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Cast metal


 The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is also possible.[6] Specific die casting alloys include: Zamak; zinc aluminium; aluminium to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium.The following is a summary of the advantages of each alloy:

-Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.

-Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.

-Magnesium: the easiest metal to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast.

-Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts.

-Silicon tombac: high-strength alloy made of copper, zinc and silicon. Often used as an alternative for investment casted steel parts.

-Lead and tin: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance. Such alloys are not used in foodservice applications for public health reasons. Type metal, an alloy of lead, tin and antimony (with sometimes traces of copper) is used for casting hand-set type in letterpress printing and hot foil blocking. Traditionally cast in hand jerk molds now predominantly die cast after the industrialisation of the type foundries. Around 1900 the slug casting machines came onto the market and added further automation, with sometimes dozens of casting machines at one newspaper office.

-Maximum weight limits for aluminium, brass, magnesium and zinc castings are approximately 70 pounds (32 kg), 10 lb (4.5 kg), 44 lb (20 kg), and 75 lb (34 kg), respectively.[9]

The material used defines the minimum section thickness and minimum draft required for a casting as outlined in the table below. The thickest section should be less than 13 mm (0.5 in), but can be greater.

There are a number of geometric features to be considered when creating a parametric model of a die casting:


Draft is the amount of slope or taper given to cores or other parts of the die cavity to allow for easy ejection of the casting from the die. All die cast surfaces that are parallel to the opening direction of the die require draft for the proper ejection of the casting from the die.[11] Die castings that feature proper draft are easier to remove from the die and result in high-quality surfaces and more precise finished product.

Fillet is the curved juncture of two surfaces that would have otherwise met at a sharp corner or edge. Simply, fillets can be added to a die casting to remove undesirable edges and corners.

Parting line represents the point at which two different sides of a mold come together. The location of the parting line defines which side of the die is the cover and which is the ejector.

Bosses are added to die castings to serve as stand-offs and mounting points for parts that will need to be mounted. For maximum integrity and strength of the die casting, bosses must have universal wall thickness.

Ribs are added to a die casting to provide added support for designs that require maximum strength without increased wall thickness.

Holes and windows require special consideration when die casting because the perimeters of these features will grip to the die steel during solidification. To counteract this affect, generous draft should be added to hole and window features.


 There are two basic types of die casting machines: hot-chamber machines and cold-chamber machines.These are rated by how much clamping force they can apply. Typical ratings are between 400 and 4,000 st (2,500 and 25,400 kg).

Hot-chamber die casting

Schematic of a hot-chamber machine

Hot-chamber die casting, also known as gooseneck machines, rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the "gooseneck". The pneumatic- or hydraulic-powered piston then forces this metal out of the gooseneck into the die. The advantages of this system include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. The disadvantages of this system are that it is limited to use with low-melting point metals and that aluminium cannot be used because it picks up some of the iron while in the molten pool. Therefore, hot-chamber machines are primarily used with zinc-, tin-, and lead-based alloys.

Cold-chamber die casting

A schematic of a cold-chamber die casting machine.

These are used when the casting alloy cannot be used in hot-chamber machines; these include aluminium, zinc alloys with a large composition of aluminium, magnesium and copper. The process for these machines start with melting the metal in a separate furnace.Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston. The biggest disadvantage of this system is the slower cycle time due to the need to transfer the molten metal from the furnace to the cold-chamber machine.

Advantages and disadvantages


 Excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first 2.5 cm (0.005 inch for the first inch) and 0.02 mm for each additional centimeter (0.002 inch for each additional inch).

Smooth cast surfaces (Ra 1–2.5 micrometres or 0.04–0.10 thou rms).

Thinner walls can be cast as compared to sand and permanent mold casting (approximately 0.75 mm or 0.030 in).

Inserts can be cast-in (such as threaded inserts, heating elements, and high strength bearing surfaces).

Reduces or eliminates secondary machining operations.

Rapid production rates.

Casting tensile strength as high as 415 megapascals (60 ksi).

Casting of low fluidity metals.

The main disadvantage to die casting is the very high capital cost. Both the casting equipment required and the dies and related components are very costly, as compared to most other casting processes. Therefore, to make die casting an economic process, a large production volume is needed. Other disadvantages are that the process is limited to high-fluidity metals, and casting weights must be between 30 grams (1 oz) and 10 kg (20 lb).[note 3][10] In the standard die casting process the final casting will have a small amount of porosity. This prevents any heat treating or welding, because the heat causes the gas in the pores to expand, which causes micro-cracks inside the part and exfoliation of the surface.Thus a related disadvantage of die casting is that it is only for parts in which softness is acceptable. Parts needing hardening (through hardening or case hardening) and tempering are not cast in dies.

 

What we can ?

Alige is the world’s fastest manufacturer of custom prototypes and on-demand production parts with manufacturing facilities in five countries.

Rapid Prototyping

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data

Plastic Injection Molding

Plastic injection molding is the most common method of producing parts out of plastic material.

Die Cast

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity.

Stereolithography

Stereolithography (SLA or SL; also known as stereolithography apparatus, optical fabrication, photo-solidification, or resin printing)

Metal Stamping

Stamping (also known as pressing) is the process of placing flat sheet metal in either blank or coil form into a stamping press where a tool and die surface forms the metal into a net shape.

CNC Machine

CNC milling is a subtractive manufacturing process that uses 3-axis milling and 5-axis indexed milling processes to rapidly cut solid plastic and metal blocks into final parts.

Choosing a Rapid Manufacturing Process

Each manufacturing process comes with its own advantages and disadvantages. From 3D printing to CNC machining and injection molding, this white paper is a highly technical look at the various rapid manufacturing processes. Weigh the benefits of each so you can focus on a process best suited for your project.

Common Applications

Get prototypes and low-volume production parts in as fast as 1 day with our industrial 3D printing, CNC machining, and injection molding services.

Selective Laser Sintering

$95

  • 1 to 50+ parts
  • Shipped in 1 to 7 days
  • complex geometries
  • functional, end-use parts

Details

Stereolithography

$95

  • 1 to 50+ parts
  • Shipped in 1 to 7 days
  • form and fit testing
  • high accuracy and surface quality

Details

Injection Molding

$1495

  • 25 parts to 10,000+ parts
  • Shipped in 1 to 15 days
  • Plastic Injection Molding
  • Overmolding & Insert Molding

Details

Selecting a Rapid Prototyping Process

Compare various 3D printing, CNC machining, and injection molding technologies to find a process best suited for your project.

Read more

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