The Precision Touch in Custom Metal Stamping

The objectives of prototyping vary widely, yet can be broken down into a few broad categories.

Part Form and Fit

The most basic needs of prototyping are to assist in the visualization of the part and to determine how it fits into and interacts with the rest of the assembly. This is referred to as the form and fit of the component. These needs are often met using a solid modeling package. The ability to create an assembly using individual solid models is a feature that is now found in most modeling packages. An increasing number of packages offer integrated animation, kinematic, and finite element analysis that can meet most form and fit needs and even basic function analysis. Stereolithography is also a viable form and fit option, however the physical and mechanical properties of a metal part are not well represented with a plastic stereolithography part.

Part Function

As the design of a product progresses, the specific response of a metal component may need to be accurately simulated. Finite element analysis is a valuable tool to initially optimize many of the mechanical properties of the component (strength, frequency response, heat and fluid transfer). However, the actual response of the component is best determined using a prototype of the same material, shape, finish and internal stresses of the final product. This information can then be fed back into a computer analysis package for further refinement if necessary.

Design Validation and Device Testing

Once a design enters the functional evaluation stage, a new level of prototyping is required. The degree of replication to the final production component must be carefully evaluated considering the effect of both the design and manufacture of the part. Simulating the manufacturing process is necessary to identify problems with residual stresses, surface finish, edge conditions, burrs, cracking, feature size tolerances and other potential problems created by a specific process. For instance, the variation between a stamped part and machined part is affected by all of these factors.

Clinical Evaluation and Clinical Trials

Devices produced for clinical evaluations and trials must perform like production devices. Therefore, the prototype manufacturing process should replicate the production process on critical components. The prototyping options available to a precision metal manufacturer at these stages are often limited by the production manufacturing process.