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