Historically, metal components for automobiles were made in foundries or sheet metal stamping facilities. These processes were not suited to small volume production, particularly the one-off designs used in prototype development. Some machinists were able to make individual metal parts using hand tools and basic milling machines, but the speed was limited because of the time and labor involved. Rapid prototype machining has revolutionized the automotive industry by allowing automobile manufacturers to craft high-performance models at a fast pace.

Today there are a number of innovative solutions available to the automotive industry for getting metal prototype parts. Here is a summary of the main technologies available.

CNC Machining

Automobile manufacturers use rapid prototyping for modeling precision-crafted tools, parts, and equipment. These parts can meet exact specifications with zero errors as typically required for automotive applications.

CNC machining of prototype parts provides an ideal solution to these stringent standards. The machines can produce parts with exacting tolerances while achieving the timing needs required of today’s design cycles. Machining metal parts using this approach is often the best way to get parts quickly. Most metals commonly used in automotive applications can be machined, including steel, aluminum, and brass (to name a few).

Laser Cutting

When metal parts that are more two-dimensional in shape are required, laser cutting is often the best option. Using CAD data or even a 2D print, the operator can manufacture one or many parts quickly. There are some limitations to the technology, depending on the thickness of the material to be cut and the material properties, but laser cutting is often a fast and inexpensive approach to getting simple brackets or body parts made for automotive prototypes.

Custom Stamping and Forming

When larger or more complex parts are needed, custom forming or stamping may be the best technique. These technologies have evolved along with machining to use CAD data to guide the production of the tools and dies needed to form the metal into the shapes required. While typically more costly than CNC machining, there are times when stamping or forming of parts is the best way to achieve your results.

Metal 3D Printing

Rapid metal prototyping now also includes 3D printing of metal parts. This evolution of the 3D prototyping technology allows rapid manufacture of small metal parts with good appearance. One benefit of this approach is the ability to build parts with intricate interior features that would be difficult to machine. However, there are drawbacks, including the lack of a good means to 3D print aluminum parts at this time.

Reliable Rapid Prototype Machining Services

Rapid prototyping is an excellent manufacturing solution for making metal prototypes. A range of options exist, so working with a service provide who has knowledge of the different technologies and knows how to optimize the approach for your product and budget is imperative. We, at Global Technology Ventures, can ensure your product design is unique and practical.

To learn more about metal prototyping services, call us today!