Cast prototypes

One of the core competences at Unnaryd Modell is to deliver verified prototypes in cast aluminium or iron. We are often involved from an early stage of the product development process and we have capacity in all necessary production areas; engineering, model making, casting and machining. This enables us to control quality, lead time as well as continuous improvements during production. We have resources and know-how to handle very complex geometries and provide such parts to the automotive industry today.

During prototype manufacturing we often start with a 3D model provided by our customer. We can handle several different file formats, the most common are STEP and IGES. Starting with the 3D model our engineers produce manufacturing documents and, where necessary, modify the 3D model for production. The work is always done in close cooperation with our customer and we are happy to suggest improvements in both design and documentation.

Depending on geometry and requested quantities we mill a casting model and core boxes, or we use 3D printing to produce the mould. After that the prototype is cast in chosen aluminium or iron alloy. We machine the castings in our 5-axis milling machines and verify that all dimensions are within tolerance. Often we perform a leakage testing before delivery. We also have washing equipment to meet cleanliness demands, e.g. for transmission parts.

In our foundry we have four melting furnaces for aluminium in sizes from 100 kg to 300 kg. We have two 500 kg induction furnaces for iron. Normal casting weights vary from a few hundred grams up to 80 kg. We have experience of casting weights up to 250 kg.

We know how important it is keeping the right quality. Independent of if the product shall be evaluated in a lab environment or if it shall be used in the field, all parameters must be accurate. To verify the quality we perform a spectrometer analysis of the alloy’s chemical composition before every casting batch. Checking the hardness of the casting as well as the micro structure in a LOM-microscope verify the right metal treatment. For aluminium, we have access to X-ray equipment where we can identify possible defects such as porosity. Heat treatment is possible in order to increase the mechanical properties of the parts. Which alloy and which heat treatment to use is decided by the geometry and the demands on the part, you are welcome to consult us which treatment we recommend.

We have high capacity and long experience producing prototypes. Our aim is to be a valuable, long-term partner to our customers and therefore we deliver complete solutions, often including assembled components. How can we help you?

Unnaryd Modell