System construction space
500 x400 x300 mm
Al, Zn, etc.
complex and thin-walled components with and without heat treatment. Flow ratio, wall thickness:length = 1:100
15 days with processing, 8–10 days without
For Rapid Prototyping in metal, we focus on the casting of prototypes and small series. In addition, we offer mechanical finishing and surface engineering services.
Cutting-edge technology with ultra-short lead times
For the production of metal prototypes in die-cast quality, our experience has led to the evolution of a process that we believe provides the optimum customer benefit.
The vacuum differential-pressure (VDD) method
The VDD process can be classified as a type of investment-casting and gypsum-molding process. Similar to investment casting, the process is computer-controlled within a casting system, in which the prototypes are cast into ceramic cuvettes. This method makes it possible to produce cast prototypes within a few days and is ideal for the production of individual functional and design prototypes as well as small series.
We use the VDD process to produce prototypes of components, which are then mass-produced via a die-casting and investment-casting process (and also to a lesser extent for gravity die castings).
The process begins with the master model
- Master model creation / lost-wax models
- (Mold making)
- (Wax casting)
- Wax-tree construction
- Manufacturing and firing ceramics
- Metal casting
- Mechanical finishing
- Surface treatment (if necessary)
In order to meet the customer's requirements for tolerances in accordance with VDG P690 A2 or A3, we manufacture our cast parts directly by means of lost models, which we produce via 3D printing (the components are produced using a Voxeljet 3D printing system). The mold-making and wax-casting steps are thus omitted and dimensional tolerances similar to those found in die casting are possible.
Basic data for metal casting
- Maximum component size: 500 x 400 x 300 mm (LxWxH)
- Maximum casting volume: 2.6 to 3 liters
- Minimum wall thickness for aluminum: 1mm
- Quantity-dependent lead time: 1 to 3 weeks for approx. 3 to 5 pcs.
- Alloys: aluminum, zinc
- Dimensional accuracy: tolerance class A1 in accordance with VDG data sheet P690 is achievable – depending on the process used for the lost-wax models and the dimension/size of the components
|Suitability||very good||good||Restrictions / requirements|
|Functional parts||Mechanical properties may vary compared to other series-production processes|
|Design parts||depending on the selected production process for the lost models, the surface quality may vary|
|For subordinate components without special surface requirements||Subsequent surface treatment is possible (smoothing, grinding, blasting, varnishing, anodizing)|
|Pre-series parts||Machining may be necessary; original materials can be used|
|Test components||Alloys similar to series material|