At ARES Prototype , we are specialized in rapid prototyping and plastic injection molding. We offer the following manufacturing services.
1. Rapid Pressure Die Casting
We produce pressure die casting molds and moldings for the following materials:
Al = Aluminum
Zn = Zinc
Mg = Magnesium (excellent value)
Post finishing includes blasting, polishing, plating, painting, printing, anodizing, and precision fine machining. Pressure die casting is a method of processing aluminum into engineering shapes by molding molten metal into hardened pressure die casting molds.
2. Rapid Precision Machining
At the precision engineering department, we offer milled parts, turned parts, CNC engineering, surface grinding, wire erosion, and EDM spark erosion. All of our parts are 100% inspected in accordance with the customer requirements. We can also provide original certificates for all of our materials including carbon steels, stainless steel, brass, copper, tool steel, titanium, aluminum and etc.
3. Polyurethane Castings
We make a master model by SLA or CNC milling process and then apply whatever surface finish which is needed for the master model. We then pour liquid silicone rubber around the master model in a casting box. Once we split the silicone rubber mold, we use it to cast up to 20 PU parts per silicone mold.
UP4280 is our most popular ABS simulant; PX522HT is best for clear parts; UP8400 is our rubber simulant. All can be colored to any Panton Number or RAL.
Also we can simulate a full range of thermoplastics and elastomers.
We can have one material over-molded with another to simulate, for example, rubber over ABS, or opaque plastic over transparent plastic. It is also possible to over-mold threaded inserts. Painting and printing after casting is also common technology we use here.
Vacuum cast prototypes can be colored and textured in the mold.
To produce high gloss clear parts, normally we use Acrylic master model which is CNC machined and then polished by hand.
SLA is a process, where a laser converts a liquid photopolymer into a solid plastic layer by layer. Each layer is different and a 3D model is built up on a perforated plate in the bath of photopolymer.
There is now a huge range of SLA materials with very good mechanical properties. We uses DSM Somos 14120 which closely simulates ABS thermoplastic. And we mostly uses SLA models or CNC models as Master Patterns to make silicone rubber molds for vacuum casting of Polyurethane.
Selective Laser Sintering was commercially developed in the mid 1980′s in Texas, although a similar process dates back to 1979. It is also a laminated manufacturing process, but uses a much higher power laser to sinter plastic powder together to form a 3D prototype. The most typical material used is Polyamide/Nylon. It is also possible to have glass filled Nylon. Historically it was considered that SLS parts were more durable than SLA, but as SLA materials improve, this gap is narrowing. SLS is also considered quite wasteful as up to 30% of all non-converted powder is removed so as to refresh the powder stock. SLA has almost no material waste.
5. CNC Machined Prototype
For plastic prototypes we use good quality ABS, PMMA , PC, ABS, POM (Delrin), PTFE (Teflon), Ultem, Noryl, Nylon etc., for better results.
For metal prototypes, we can machine aluminums, stainless steel, brass, copper based materials, and even hardened tool-steel. We use heat-shrink cutter holders for our high-speed spindles to ensure cutting accuracy.
Delivery time is typically from 2 to 5 days plus Fedex or DHL shipping – normally 2 days. We often do projects with 25 to 500 sets of components by CNC machining – this is simply because a simulant material will not suffice for the application.
6. Rapid plastic Injection Molding
We use low-cost P20 soft-tool-steel or 7075 Aluminium to make the core, cavity & ejector plates and to insert these into a Master Unit Die (MUD) base. We don’t add cooling ways or other costly trimmings to the tool. This is as basic as it gets and is similar to many of the ‘rapid injection molding’ services offered elsewhere in the World today. For polished or high-gloss parts we normally use NAK-80 a polishing stainless steel.