A Prototype Aluminium Mould is a production process in steel: cooling, gating, venting and ejection have to work together before the first acceptable part appears. The Prototype Aluminium Mould described here is built in NAK80 steel and a textured finish and developed for consumer electronics. mould design, steel cutting, EDM detail, fitting and tool tryout is applied with tool life and the maintenance interval agreed before building starts.
The parts that matter most are the interfaces: bores, sealing faces, threads and mounting patterns. Those are held to cavity tolerance ±0.02 mm, verified against the drawing, and recorded before anything is packed.
Specification
| Process | Mould design, steel cutting, edm detail, fitting and tool tryout |
|---|---|
| Material / configuration | NAK80 steel and a textured finish |
| Size / capacity | 2 to 64 cavities |
| Tolerance | cavity tolerance ±0.02 mm |
| Surface finish | SPI or VDI finish as specified |
| Application | prototype aluminium mould for consumer electronics |
| Inspection | Dimensional report, material certificate, first article report on request |
| Lead time | 7–15 working days for samples, 3–4 weeks for production |
| Minimum order | 1 piece for prototypes, from 50 pieces for production pricing |
Manufacturing process
The operation sequence is decided before the first chip is cut: roughing to leave even stock, semi-finishing, then mould design, steel cutting, EDM detail, fitting and tool tryout as the final operation. That order is what keeps cavity tolerance ±0.02 mm stable as the batch runs and the machine warms up.
Material is purchased against a certificate and checked on receipt, so the composition is known before any cutting starts. Work in progress is identified by part number and operation, and the finished parts are deburred, cleaned and protected before they leave the machine area.
Typical applications
Most of the work supplied in this category falls into the following examples.
- Electronic housings and connectors.
- Automotive interior components.
- Medical device disposables.
- Appliance control panels.
- Packaging closures.
Quality control and documentation
Every batch is measured against the drawing with calibrated equipment, and results are recorded against the part number rather than kept on a scrap of paper.
Material certificates to EN 10204 3.1, dimensional reports and first article inspection reports are issued with the shipment where the application requires them. Calibration dates and measurement uncertainty are recorded alongside every result.
Ordering, lead time and packaging
Quotations are returned within one working day of a complete drawing package. Lead time is quoted from drawing approval, not from the date of enquiry.
Frequently asked questions
How long does a mould take to build?
Prototype aluminium tools run 2 to 3 weeks, hardened production tools 6 to 10 weeks depending on cavity count, slides and the amount of EDM detail required.
What determines the steel choice?
Annual volume and resin. Abrasive or corrosive materials and volumes above a few hundred thousand shots justify hardened steel, while short runs are cheaper in aluminium.
What file formats do you need for a quotation?
STEP or IGES for the 3D model and a PDF drawing with tolerances, material and surface finish called out. Native files from SolidWorks, Creo or Inventor are also accepted.
To discuss prototype aluminium mould requirements, send the model and the drawing with the quantities required. Feedback on manufacturability is given free of charge before any order is placed.
