PrototypingVisualization in Metal and Plastic
Prototype production using ultra-precision machining
Prototype production using ultra-precision machining is an ideal way of quickly evaluating the product design and identifying optimization potential without having to invest in a prototype tool. State-of-the-art HSC technology, diamond milling machines and diamond lathes are available for this purpose in our Ultra Precision Competence Center. The diamond tools deliver sub-micron accuracy and surface finishes with roughnesses below 10 nm. With a state-of-the-art spindle, using fly-cutting, planing machining and with up to four-axis ultra-precision movement, the introduction of the finest linear and microstructures is possible, as is the machining of large workpieces up to 650 mm in diameter.
- Rapid verification of product design
- Cost advantage over injection-molded prototypes for low volumes
- Prototypes with optical quality and complex free-form geometries possible
Prototyping with VIAOPTIC
Production of prototypes by injection molding
If sample parts are to be manufactured in large quantities and made available for further evaluation in the subsequent series material, prototype production using the injection molding process makes sense. This offers the advantage of being able to consider various process influences under series production conditions in order to be able to better estimate the achievable tolerances before series production begins. When constructing the prototype tools, material and manufacturing alternatives are used which allow a significant price advantage compared to the later series tool. In addition, under certain conditions, sample parts can be manufactured by inserting individual tool inserts into an existing master tool. The optical surfaces are created in each case by mold inserts which are manufactured from aluminum or steel, for example, by means of ultra-precision machining.
- Design validation with near-series prototypes made from original material
- Cost advantage over UP-produced prototypes for high volumes
- Tolerance analysis under series production conditions possible
Possibilities and solutions
- Reflectors
- Lenses
- Spherical and aspherical surfaces
- Freeform surfaces
- Microstructures
Equipment and machinery
- CNC-controlled turning, milling and drilling
- State-of-the-art 5-axis HSC machining
- Ultra-precision machines for workpieces up to 650 mm in diameter
- Modern ultrasonic technology for machining of certain steels
