How to produce aluminum prototypes for installed and leak tests

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If you need to produce aluminum prototypes and you are not sure about the production technology that best suits your needs, read this article carefully. With this case history we will illustrate the elements that led our client to the choice of the production process and all the steps performed, choices that have proven successful in validating the development of a highly innovative product and confirming the undisputed leadership in the screwdriver market impulse.

Before telling you the story of this project need to share information on how to design, technologies and production processes suitable for the production of aluminum prototypes

One of the steps fundamental to approve the engineering phases of a new product is the creation of prototypes that are generally used to validate the geometry that is developing, carry out all the tests of assembly, mechanical seal, functional and stress checks, validations ergonomic and aesthetic, wind tunnel tests, certification tests and more

For this project in in particular there was the need to perform reliability and tightness tests mechanics on the product for which the customer necessarily needed create components with the final production material, aluminum.

The way we can produce aluminum prototypes are two:

  1. Milling
  2. Direct Metal Laser Sintering DMLS

The mechanical milling process allows to produce prototypes in aluminum but also in other metallic or plastic materials; to view all the metals that can be processed in our workshop, consult the infographics on hard and soft metals. With this technology it is possible to obtain a degree of precision not yet achievable by most of the additive rapid prototyping machines, to read carefully all the advantages of this technology click here

Laser sintering of metal powders is a relatively young 3d printing technology. Also in this case it is possible to produce prototypes in aluminum but also other materials such as steel, titanium, bronze, copper and more. The process is the same as for nylon sintering, it must be added that the prototype must almost certainly be worked on with a machine tool, here is a short video to view all the steps of the process.

In general the two processes they are poles apart first of all in the CAD design but also in the production; in the first case we start from a full block to remove the surplus material, in the second case only the material is aggregated which is used for the production of the piece, which is why you can get significant advantages in the use of metal sintering such as possibility of creating very complex geometries, much lighter, pieces unique and faster times.

In this specific case we are talking about Dino Paoli Srl, a leading company in the production of screwdrivers for the Motorsport, Automotive and Industry sectors. The product that Dino Paoli has developed is the Fast Shuttle: a highly innovative and completely made in Italy rear cover that can be mounted on different screwdriver models. The system is designed to facilitate the operator as much as possible and allows you to quickly reverse screwing and unscrewing activities without taking your hand off thanks to a special lever. At first, the need to perform functional and sealing tests of the product led to the creation of two prototypes of the protective casing and the 6082 anticorodal aluminum lever. The choice to use mechanical milling processes for aluminum prototypes was immediate, given the simplicity of the geometry. After the first prototype samples, Dino Paoli moved to definitive production, always making use of mechanical milling processes. The print runs, referring to a highly customized and niche product, are suitable for this production process.

Pit Stops are even faster thanks to the Fast Shuttle kit: a cutting-edge tool that can really make a difference in the race and can be crucial for victory. Thanks to Dino Paoli and all his staff for choosing COESUM in this project.

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