3D Prototype Castings in Aluminium and Magnesium

With over 20 years of experience, we combine 3D printing with plaster casting to create top-quality prototype castings in aluminum, magnesium, and zinc.

We produce initial prototype castings within just 5-10 working days. After casting, we can machine the castings in our state-of-the-art CNC machining department, where a total of 19 high-tech machining centers are available.

100% In-house production
To guarantee prompt deliveries, we maintain 100% in-house production capabilities. Check out the video below and learn more about our streamlined process.

3D Prototype Casting in Aluminium and Magnesium

Bibbi Klemmensen, Key Account Manager
Tel: (+45) 6172 0402
Mail: bik@formkon.dk

Short introduction video to our 3D Prototype Castings process. For full version please go the bottom of this page.

3D Prototype castings - Step by step

Design of gating
The first step is 3D design of the gating system and adding machining allowance for the subsequent CNC machining process.

3D printing of PMMA models
The number of finished prototype castings to be used will be printed as PMMA models first. The models are printed on our large in-house Voxeljet VX800 printer.

Plaster mould production
The printed PMMA models are embedded in plaster. The PMMA models are then burnt off at approximately 700 degrees. This forms a cavity in the plaster mould corresponding to the finished prototype castings in aluminium or magnesium.

Molten aluminium or magnesium is poured into the plaster mould. When set, the plaster mould is smashed and plaster residue and gating system is removed from the cast prototype.

When the prototypes are cast, we can carry out complex CNC machining at our state-of-the-art machining department.

Quality control
Before shipping the prototypes, we can measure and check them to ensure that they fully meet the customer’s requirements.

Technical specifications

• Aluminium AlSi7Mg – EN AC-42000
• Aluminium AlSi10Mg – EN AC-43200
• Aluminium AlSi10MnMg – EN AC-43500
• Aluminium AlSi12(Fe) – EN AC-44300 – 230 D
• Aluminium AlSi9Cu3(Fe) – EN AC-46000 – 226 D
• Magnesium AZ91
• Magnesium AM50
• Magnesium AM60
• Zink Zamak 5

Other alloys on request.

Casting tolerances according to VDG P690, Accuracy grade D1.

1-50 pcs.

700mm x 400mm x 400mm (larger items may be possible but will require further studies).

Ra 6 to Ra 9

Why Cast Prototypes? The Advantages

In the manufacturing of prototypes from materials like aluminum or magnesium, today there are a variety of production methods available. Although alternatives such as 3D printing directly in aluminium or CNC milling from solid may be more economical and faster in some cases, casting prototypes offers significant advantages, especially when serial production is later to be carried out by high pressure die casting.

Prototype castings allows for precise selection of the alloy, which is crucial for achieving realistic mechanical and thermal properties as well as conducting corrosion tests. With our specialized casting process, the designer can focus on optimizing the design for die casting, resulting in parts with precise specifications, including appropriate wall thicknesses and radii.

One of the main advantages of casting prototypes is the ability to conduct comprehensive tests that closely mimic actual production conditions. This enables designers to identify potential issues early in the development process and make the necessary adjustments, ultimately saving both time and resources.

Furthermore, casting prototypes can help reduce the risk of errors in serial production. By gaining a deeper understanding of the behavior and properties of the material through prototype casting, potential challenges can be identified and solved before they become costly problems in full production.

Overall, casting prototypes in aluminum or magnesium enables a comprehensive and efficient development process that combines technical expertise with practical experience to achieve optimal results in terms of both product quality and production costs.

Full video of case study from our 3D Prototype Castings process