From aerospace to electronics, metal prototypes are very important for many companies because effective metal prototypes can lead to better finished products.
Currently, the commonly used processes for manufacturing metal prototypes include CNC machining, casting, sheet metal forming, and 3D printing; The commonly used materials are aluminum and steel. Among them, aluminum is the most widely used, mainly due to the following reasons.
Excellent processability
Aluminum has excellent machinability. For example, the finished product is usually made of carbon steel. Comparing aluminum alloy with 1212 steel, the cutting speed of aluminum is 3.6 times that of steel. Therefore, the processing time is faster, and although the durability may be somewhat poor, it is completely sufficient as a prototype.
In addition, various processes can be used to process aluminum alloys, such as CNC turning, CNC milling, grinding, polishing, honing, drilling and tapping, electrical discharge machining (EDM), electrochemical machining, slotting, and so on.
Extremely high accuracy and surface finish
CNC machined aluminum alloy workpieces can achieve optimal surface finish while accurately controlling tolerances.
Corrosion resistance
Aluminum has unique advantages in corrosion resistance. A thin oxide layer is formed on the surface of aluminum, which serves to protect the metal from external harmful substances.
Strong weight strength ratio
Aluminum alloy is three times lighter than steel, making it very lightweight. At the same time, some aluminum alloys have been improved to have good strength.
Nonmagnetic alloy
Aluminum does not react with magnets and can be used to make components that require resistance to magnetic fields. And compared to other similar alloys, aluminum alloys are cheaper.
Medical use
Some aluminum alloys can be used in the medical industry. For example, 6063, 6061, and 3003 alloys are fully compatible with human tissue.
High conductivity
Aluminum machining can be used for electrical prototyping, especially when manufacturing complex electrodes, numerically controlled machining of aluminum parts.