Aluminum and magnesium parts are two prototype metals widely used in many industries. Today, most automotive companies use prototype die casting for design validation, sometimes before starting production.
Prototype applications for die casting do not require long life, short cycle times, high yields, and low part costs, and production die casting tools/molds are designed for these purposes. As a result, prototype die casting tools are made from less expensive steels such as P20 and in many cases reuse existing die bases to reduce time and cost. This technique allows for prototyping of parts using the exact same materials used for high-volume production, without the initial investment in expensive and complex production tools.
Other strategies, such as the use of single-chamber molds, modular tooling designs using interchangeable or interchangeable tool blades, and manufacturing inserts from pre-hardened and non-nitrided steels, significantly reduce manufacturing time and cost. The cooling system can also be optimized to reduce costs, as cycle times do not need to be as fast as in high-volume production. Compared to production die casting, prototype tools can be made quickly in 4 to 6 weeks, depending on the geometry of the final part.
When using aluminum die casting prototypes, it is also relatively easy to make design changes. Because the mold inserts are interchangeable and are manufactured from inexpensive steel, design changes can be implemented quickly. Similarly, a series of parts that differ slightly in features can be manufactured with inserts, avoiding expensive multiple tools. This allows for quick validation of the design before full-scale production, creating parts that closely resemble the final product.