Service – DDPROTOTYPE

Rapid Prototyping

Martin.mu — Sat, 08 Jun 2024 02:48:47 +0000

DDPROTOTYPE provides one-stop service to meet your rapid prototyping and low-volume manufacturing needs. Since 2008, our sales have increased by more than 50% annually. Our quality rapid prototype and service recognized by our global clients. We are happy to provide customer with rapid prototype to validate their designs. Sometimes, we will provide FOC prototypes to our customers for checking our quality and service. Our mission is to provide high quality parts at a lower price.

Rapid protoyping involved machining processing

At DDPROTOTYPE, we provide a series of rapid prototyping solutions to help designers, engineers and manufacturers, we have various machining processing to cover the production for different rapid prototyping request. Also we can work out a prototype in a short time and sent it to clients for design validation. For some parts with assmble relations, we would arrange on-site assemble for assure it fits well before delivery it to customers.

Our Services Include:

1: Product manufacturability evaluation
2: 3D Printing (SLS, SLA)
3: CNC Machining (milling, turning)
4: Vacuum Casting
5: Rapid Tooling
6: Plastic injection Molding
7: Die casting
8: Sheet metal machining

Rapid Prototyping Video | DDPROTOTYPE

Advantages of DDPROTOTYPE

1.Intelligent Quotations for Every Project

To help you get the ideal rate for our rapid prototyping services, we never require a minimum order volume or minimum dollar value. Plus, we use state-of-the-art AI quotation algorithms to get you your quote quickly (24 hours or less for nearly all projects).

2.Reliability and Rapid Completion Times

In rapid manufacturing, time is of the essence—however, speed shouldn’t compromise quality. DDPROTOTYPR gives you the best of both. We have 2- to 48-hour response times on RFQ’s 95% of the time, as well as a 90%+ OTD (on-time delivery) against our commitments.

3.An Extensive Range of In-House Services

To meet the diverse low-volume production needs of our worldwide clientele, our team proudly provides a wide range of in-house manufacturing services deployed with industry-leading agility. These include plastic injection molding, CNC machining, pressure die-casting and more. You can trust us to manage your production with the precision and quality you deserve.

4：A Full Suite of Finishing Services

Many CNC machined parts require some form of post-finishing before they are ready to be put to use. From bead blasting to polishing, anodizing to plating, laser etching to painting, we offer every surface finish you need to make a great finished part.

Check Out Our Advanced Equipments >>>

CNC Machining

DDPROTOTYPE provide a variety of precision CNC machining services including CNC milling, CNC turning, EDM and wire EDM, and surface grinding. With 100+ sets Multi-axis CNC precision machining centers, 40+ senior engineering with rich professional experience to control the tolerance within 0.005mm for your precision parts.

Vacuum Casting (Polyurethane Casting)

Vacuum casting is a good method for manufacturing rigid or flexible parts, and is one of the ideal choices for prototype machining, assembly testing, concept verification and Exhibition demonstration. These parts can be made from hundreds of casting polymers. Our vacuum casting service generally uses 3D printing or CNC machining to manufacture main mold and silicone mold. The precision of parts in vacuum casting depends on the main model, the geometric structure of parts and the casting materials. Usually, the predicted shrinkage rate is + 0.15%.

3D Printing

3D printing is a revolutionary technology. This method uses 3D computer data of the product to realize the principle of product prototype manufacturing directly. SLA and SLS are two mature selective laser sintering rapid prototyping technologies. The materials used in SLA are mainly photosensitive resins such as ABS; The materials used in SLS is Nylon and Nylon with glass fiber filled.3D printing is common used in Rapid Prototyping Service in China.

Rapid tooling

Combined with our CNC milling and turning capabilities and professional knowledge of plastic injection molding, DDPROTOTYPE provides rapid tooling services to produce high-quality plastic parts in various materials which is totally the same as mass production. Rapid tooling is the bridge of prototype and large-scale manufacturing. It helps designs to enter the market quickly, and the cost is much lower than that of large-scale manufacturing.

Your ideal prototyping partner

Every design engineer will request protoype for do design validation, our engineering team will help you to find the best prototyping solution for your project. We can guranttee you can get qick response and professional technical support in prototype with our rich experience in rapid protoyping.

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CNC Machining Service

Martin.mu — Fri, 07 Jun 2024 23:10:05 +0000

DDPROTOTYPE provide a variety of precision CNC machining services including CNC milling, CNC turning, EDM and wire EDM, and surface grinding. With 50+ sets Multi-axis CNC precision machining centers, 40+ senior engineering with rich professional experience to control the tolerance within 0.005mm for your precision parts. If you need a reliable rapid prototyping manufacturing partner to support you, DDPROTOTYPE will be the best choice for you. Keep learning more about us, or contact us now for Get an instant quote.

CNC Milling Service

CNC Turning Service

CNC Milling service can be applied to manufacture highly precision and sophisticated parts, such as the parts with 3D curved surface and complex geometries. CNC milling is universal , accurate and repeatable, can machining many different type of structure precision parts, including holes, curves, grooves, angle shapes and channels. Only one time clamping required, and using different cutters to achieve the different shape, tolerance can be controlled within ±0.005mm.

CNC turning using drill, expanding drill, reamer, tap, threading die and knurling and other corresponding tools, machining some round or ball-shaped and taper parts, as well as special external and internal threading. Precision can achieve 0.005mm, surface roughness can follow ISO 2632/1-1975 standard Unless otherwise specified. This processing method can manufacture various engineering plastics and different metals, such as steel, copper, aluminum, magnesium , PEEK POM PA ABS PP PC PMMA PTEF and so on.

CNC Machining Video | DDPROTOTYPE

CNC Machining Capability

At DDPROTOTYPE, Our experienced machinists can create quality parts that meet or exceed your expectations for precision, quality, and turnaround time. We can handle with stainless steel, aluminum, titanium, brass and other metals and engineering plastics into precise parts through milling or turning machining to meet different customers needs in different industry area, such as national defense, automatic, medical, electronics and robotics. surface roughness can follow ISO 2632/1-1975 standard Unless otherwise specified, High precision to 0.005mm. Special dimension please contact us for details.

CNC machining service at DDPROTOTYPE not only limit to rapid prototype manufacturing.Over 10+ senior CNC programmers with rich experience, according to the drawing requirement to choose difference CNC machining centers and cutter for manufacturing, can cover production for low-volume and full-scale orders, quantity can start from 1pc to 100Kpcs. During the machining process, for the special dimensions we will arrange on-site inspection. When parts finished the production, we will arrange full dimensions inspection and provide inspection report before delivery. DDPROTOTYPE provide the design validation and assemble service also. Contact us now for start CNC machining project.

Upload the CAD file to info@ddprototype to receive quotation within 12 hours.

Advantage of Our CNC Machining Service

1. Experienced machinist team has solved many complicated projects. For complex and high precision projects, we have a series of solutions about deep drilling, thin wall thickness, irregular structure, and so on.
2. There are 100+ in-house manufacturing and testing machines, including Jingdiao 3 and 5 axis CNC machines, CMM. Travel max to 2000/800/350mm. High-precision tolerance to 0.005mm.depending on customer requirements.
3. Located in Shenzhen China with completed supply-chain, various materials optional meet your special requirements. 50+ operators with 7*24 hours working time, short your developing schedule and cost saving. 3~7 days worldwide delivery, 40% to 70% off than Europe/America.
4.With 20+ years of CNC machining experience, can streamline machining path to min, machining parts in the fastest time and deliver on time , which can greatly save processing time,and reducing machining costs.

CNC Machining Auxiliary Process

To achieve some specical structural requirements, such as undercut structure, deep groove and vertical structure, we will use manual milling machine, EDM, wire cutting, grinding machine, deep hole drilling machine to assist machining to meet customers’ different requirement in dimensions and structure.

EDM is an important auxiliary manufacturing process of CNC machining, often used in mold manufacturing, but also for some special structure of prototype machining. Using conductive graphite or copper electrodes immersed in the dielectric, when applied with a high voltage current, sparks are generated on the copper tool wall, etching away excess material and fulfilling the customer’s critical radius angle requirements.

Surface grinding is a process for making parts with extremely flat and smooth surfaces. When the workpiece is fixed in the fixture, It moves back and forth across the surface with a precision grinding wheel, Thus the surface roughness can be greatly improved.

Standard tolerance for CNC machining

About tolerance, unless otherwise specified, For CNC milling and CNC turning parts, we follow DIN-2768-1-fine tolerance standard; For vacuum casting and sheet metal parts, we follow DIN-2768-1-medium tolerance standard; For assembly parts to be welded, we follow DIN-2768-1- coarse tolerance;
Before starting machining, our programming engineer, production engineer and quality engineer will discuss the machining plan of the product, whether the tolerance can be achieved, and the testing fixtures and tools needed. For parts that need to be manufactured on multiple surfaces and require high precision, we will test them while machining and prepare testing fixtures according to requirements to to ensure accuracy.

Above tolerances won’t apply to sheet metal parts, welded assembly part , and overall dimensions over 400mm. For any special tolerance requirements, please feel free to contact our team.

CNC Machining Finishing Service

For appearance prototype, in order to show the final intuitive effect of the product, many clients need to do a variety of special surface finishing in accordance with the mass production requirements; Our team are able to deal with aluminum anodizing (various colors available according to Pantone Number provided), steel passivation, metal/plastic painting, plastic vacuum plating, electrophoretic coating, brushing, electropolishing, mirror polishing, silk screen printing, etc., to meet a variety of requirements.

To learn More About Anodized Aluminum, Please Click Here

CNC FINISHING AND POST-PROCESSING OPTIONS
As machined (standard)	Bead blasting	Polishing	Heat treating
Anodizing	Brushing	Screen printing	Passivating
Powder coating	Painting	Engraving	Plating……

Surface Roughness

CNC machining is a highly accurate and precise manufacturing process that can create parts with tolerances as tight as 0.005 mm. However, CNC machining leaves cutting marks that create a level of roughness on the finished prototype surface.In manufacturing, there are specific Ra values that are considered industry standards, as specified in ISO 2632-1. These are the values that may be specified during CNC machining. They range from 12.5 um to 0.025 um and apply to all kinds of manufacturing and post-processing operations.

full dimensional inspection reports

Surface finish stems from the understanding of the surface hardening rate of a given material. No worry. DDPROTOTYPE is your best choice for quality CNC machining and finishing services at the best prices. We offer full dimensional inspection reports, so you can be sure of desired results. We also carry out different finishing processes ranging from anodizing, electroplating, bead blasting to polishing, brushing, and more.

For the parts with assembly relations, we will conduct trial assembly before delivery, purpose for guranttee the parts fit well when customer received it.

At the same time for all parts with 2D drawings, we will arrange full dimensions inspection and send inspection report to customer, which is a most important internal working procedure at DDPROTOTYPE.

Design For CNC Maching

Although CNC machining is versatile, but there still have some processing limitation because of design. So when we design a part, we should take the design rules into consideration to guranttee the CNC machining process smoothly. The limitation of CNC design are mainly due to the mechanics of the process, the geometry of parts, and the limitations of cutting tools.

To take full advantage of CNC machining, designers need to follow manufacturing design rules to make the product has feasibility of machining. If you need support, we can provide some suggestions in order to avoid the machining failure due to design defects. We have done some basic and common design defects for reference.

Advance 3 axis CNC Machining Center

If your prototype is not very complex and your budget is limited, it is also a good choice to choose 3-axis CNC machining service. Also it is a cost-effective choice. In many cases, 3-axis CNC machining is a popular prototype machining method. DDPROTOTYPE purchased another 20 sets Jingdiao equipments, tolerance can achieve to 0.005 mm. Quota Our quality inspection equipment, DDPEOTOTYPE is fully capable of meeting your needs, even the quality will exceed your expectations.
3-axis machining is processed by linear feed axes X, Y and Z.
Machining features: The direction of the cutting tool remains constant throughout the cutting path.
After the machining parts are clamped once, the CNC system can control the machine tool to select and replace the tool automatically according to different working procedures.

Changing machine tool spindle speed, feed and tool relative workpiece movement track and other auxiliary functions automatically, continuously proceeding with milling, drilling, tapping and other processes on workpiece automatically.

Because the machining center can be centralized, accomplish a variety of processes automatically, avoid manual operation error, reduce the workpiece clamping, measuring and machine tool adjustment time a, which greatly improve the processing efficiency and processing accuracy, with higher economic benefits.

5 Axis CNC Machining Center

Advanced 5-axis vertical machining center, model JDGR-400T, can process and milling more complex parts with high precision. 5Axis CNC machining Service will take your manufacturing process to a higher level, even beyond the expectations of customers.Complex parts are perfect for GMU-400T. With its generous travels and 5-axis capabilities, you’ll easily reduce setups and part handling, while increasing feature-to-feature accuracy.

Our 5-axis CNC machining centers make turned and milled parts from a wide range of plastic, and metal alloy materials – such as aluminum, brass, nickel, and steel, both mild and stainless steel. We use industry-leading software like Autodesk PowerMill and CGTech Vericut, and we have over 8,000 + genuine Gühring cutters in stock.

5-axis CNC machining is an effective means to reduce setups and increase accuracy for multi-sided and complex parts. The JDGR 400T has an integrated dual-axis trunnion table with a 400 mm diameter platter that features standard T-slots and a precision pilot bore for fixturing versatility. The trunnion provides -120 and 90 degrees of tilt and 360 degrees of rotation to provide excellent tool clearance and large part capacity.

5 Axis CNC Machining Center- JDGR 400T

Tolerances for feature size:

Standard +/-.002mm
Minimum +/-.002 for metal and +/-.003 for plastic

Tolerances for hole diameter:

Standard +/-.002 mm
Minimum +/-.0004 mm for metal and +/-.001 mm for plastic

Tolerances for Flatness, Run Out, Cylindricity, Perpendicularity and other Geometry:

Standard+/-.005 mm
Minimum +/-.002 mm is possible per geometry dependent

X/Y/Z axis working stroke：450mm/680 mm/400mm

Maximum Speed：20000 rpm

Tool Magazine Capacity：36

Helping Our Customers

Richard, from the United States, found us through Google search and manufactured an engine cover. The prototype machining is very complex, there are many apertures, and the tolerance requirements are more stringent. Richard is an industrial designer who has worked with many prototyping companies. When DDPROTOTYPE sent the hood to Richard, Richard gave a high appraisal, indicating long-term strategic partnership with DDPROTOTYPE. Richard’s colleagues have now fully recognized us. Send your 3D drawings, get competitive quotations and feedback within 12 hours.

More Successful Case Study

Plastic and Metal Materials

We stock more than 60+ engineering-grade plastic and metal materials that are suitable for various part applications and industries. Materials range from plastics like ABS, polycarbonate, nylon, and PEEK to aluminum, stainless steel, magnesium, and copper.

VIEW More Material >>>>

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Manufacturing

Martin.mu — Fri, 07 Jun 2024 21:52:17 +0000

Low-volume manufacturing can be achieved through different parts machining methods, CNC machining, 3D printing, vacuum casting and rapid tooling. It is a bridge and supplement from prototype machining to mass production. DDPROTOTYPE is a company that can provide low-volume manufacturing. We have unparalleled expertise and can provide high quality and repeatability for each part. According to your project objectives and expectations, we are the best way for low-volume manufacturing. We provide cost-effective and rational suggestions from design, materials, production process, manufacturability

Low-Volume Manufacturing is Hopeful

Consumers expect more customized and diversified products than ever before. With the shortening of product life cycle and the shortening of new product release cycle, flexible innovation and time-to-market are critical to your strategy. Driven by these factors, product design develops rapidly, and product developers turn their attention from large-scale production to low-volume manufacturing.

Low-volume manufacturing usually involves the production range of 100 to 100K parts. Compared with many risks and costs associated with over-expansion to “large-scale commercialization”, small batch manufacturing does reduce risks, make design more flexible, shorten product launch time, and create opportunities to save production costs. Low-volume manufacturing solutions benefit all stakeholders throughout the product life cycle, from design to manufacturing, to supply chains and consumers.

Low-volume manufacturing Video | DDPROTOTYPE

Advantages of Low-volume Manufacturing

Design iteration is more flexible

Before mass production, expensive production moulds need to be invested. Creating low-volume product runs makes it easier to verify design, assembly and manufacturability. Fast design iterations after the first trial run can further optimize and improve the product before facing more consumers.

Fast turnover, low cost

As the cost of mould and design becomes a key component of project budget, because of faster iteration speed and shorter cycle time, low-volume manufacturing is usually more cost-effective than mass production, thus reducing the total cost of production.

Reducing the gap with production

Producing hundreds to thousands of pre-production components can be a very useful step before turning to mass production. Trial run will narrow the gap between prototype and production, complete functional, shape matching test and engineering design verification faster, allow you to show the final product to potential consumers and salespeople, and allow any problems to be found and corrected well before mass production.

Reduce the time to market

With the increasingly fierce competition in product market, becoming the first company to promote the market with unique products can contribute between success and failure. The combination of highly competitive and unpredictable markets puts more and more pressure on developers and designers to create high-quality products in the shortest possible time.

Application of Low Volume Manufacturing

1 Production-level Approaches to Matching Functional Prototypes with Final Products

2 It is a bridge between prototype processing and mass production.

3 Pre-production components for validation testing

4 Pioneer for Injection Molding Production

5 High quality customized products

6 Fast parts machining, more in line with your budget needs

Let DDPROTOTYPE meet all your low-volume manufacturing needs

CNC machining plays an important role in the customized machining of plastic and metal parts. low-volume manufacturing in CNC machining is also a good evaluation solution for low-volume manufacturing.As a professional company of CNC machining, DDPROTOTYP provides services to customers from all walks by manufacturing high-quality precision machining parts. Excellent equipment combined with unparalleled knowledge and experience of our team provides us with a huge dvantage in low-volume manufacturing. We provide one-stop service for all low-volume manufacturing projects in China. Whether you need production-grade plastics, various metals or custom-made aluminium parts, DDPROTOTYPE can provide you with any material and quantity of low-volume manufacturing services.

According to your industry or the parts/products you are manufacturing, parts/products are manufactured using rapid tools or independent parts/products manufacturing technologies (such as 3D printing, CNC machining and vacuum casting).

If you are in the automotive industry, low volume manufacturing services can produce a rapid tool that can provide you with 50,000 to 100,000 parts. If you are in the medical field, low-volume manufacturing services can provide you with 1000 parts. If you are in the prototype testing stage of a new product, low-volume manufacturing services can provide you with 50-100 parts. With the increasing speed of manufacturing parts, CNC machining and 3D printing are becoming more and more important in the field of low-volume manufacturing. Vacuum casting is also a good choice for low-volume manufacturing and a relatively low-cost option. Whether your low-volume manufacturing needs are 50 parts or 50,000 parts, DDPROTOTYPE can meet your needs with high quality.

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Save time and money (automobile example) – automobile tools can be some of the most expensive tools. High capacity, strict tolerance, special resin, complex structure, and complexity will increase costs and prolong tool build time. There is a series of chain effects when the pressure of a bad tool slows down or stops running the project. It is necessary for 100 tools to work harmoniously at the same time in order to provide high-value automotive parts to the market as planned, so the status of automotive tools will be very important. If low-volume fast tools (or more) are introduced into automotive tools, the design can be implemented and validated more quickly. In addition, identify/repair any design defects early in the product development process. For example, when a car manufacturer introduces new part design into an existing overall design or changes the surface finish of a part, it can use a quick tool that costs only one tenth of the price of a large-scale production tool, so that you can verify the design as early as possible and find problems as early as possible. In the long run, it will save time and money eventually.

CNC Machining

No Tools Needed. Parts can be very rugged, with a large number of high-quality finishing service and materials to choose from. We can easily achieve rigorous tolerances and the ability to repeat results and increase productivity.

3D Printing

No Tools. The traditional method may not be able to manufacture the perfect choice of complex parts, rapid turnover.

Vacuum casting

You may need low volume production to test the market. Vacuum casting is an excellent choice without the cost of metal or aluminium tools (vacuum casting needs machining, but it is very cheap, small, silica gel tools). If done well, it can create high-quality parts/products for sales units. Multiple iterations that can advance sales or test design are critical for collecting design improvements. DDPROTOTYPE provides a variety of surface finishing service, provides a variety of plastic materials,and fast turnover.

Rapid tooling

Low Cost Injection Molding. The quality and characteristics of parts are the same as those of mass injection moulds, but they are delivered in a short time compared with mass moulds. Can quickly test a variety of resins to help determine the best mass production options.

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When you consider low-volume manufacturing, don’t consider increasing product development time and cost. Consider faster design validation, leading to earlier revenue funding, providing funds for improved design, and thus winning mass market penetration. Low volume manufacturing minimizes the capital risk of your important projects.

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Vacuum Casting

Martin.mu — Fri, 07 Jun 2024 18:33:58 +0000

DDPROTOTYPE is fully capable of meeting your polyurethane vacuum casting needs. With many years of professional experience and advanced equipments, we could manufacture parts to meet your requirements, even exceed your expectations, and with fast turnarounds. Vacuum casting is a good method for manufacturing rigid or flexible parts, and is one of the ideal choices for prototype manufacturing, assembly testing, concept verification and Exhibition demonstration. These parts can be made from hundreds of casting polymers. Our vacuum casting service generally uses 3D printing or CNC machining to manufacture main mold and silicone mold. The precision of parts in vacuum casting depends on the main model, the geometric structure of parts and the casting materials. Usually, the predicted shrinkage rate is + 0.15%.

What is Vacuum Casting?

Vacuum casting service is a manufacturing technology that uses vacuum to absorb liquid materials into molds. Vacuum casting technology has obvious advantages, especially for parts with undercut or detail. This process starts with a master model, which DDPROTOTYPE creates using a CNC machining or 3D printing. The main model is then immersed in liquid silicone resin, which is cured and molded. Once it is cut and the main model is removed, the silicone molding can be put into use. In the next stage, liquid resin needs to be poured into the mould, because vacuum can remove bubbles to ensure smooth surface. The resin is then partially cured and removed from the silicone mold, which can be reused about 20 times. Each resin component is an exact copy of the original master model.

Technical Specifications

1 Standard lead time: Up to 10 copies within 15 working days
2 Standard accuracy : ±0.3% (with a lower limit on ± 0.3 mm on dimensions smaller than 100 mm)
3 Minimum wall thickness: To ensure that the mold is filled properly, a wall thickness of at least 0.75 mm is necessary. For best results, we recommend a wall thickness of at least 1.5 mm
4 Maximum part dimensions: The size of the mold is limited by the dimensions of the vacuum chamber (1900 x 900 x 750 mm) and by the volume of the product (maximum volume: 10 liters)
5 Typical quantities: Up to 25 copies per mold (depending on the mold’s complexity and the casting materials)
6 Surface structure: High-quality surface finish comparable to injection molding

Why choose Vacuum Casting?

Silicone molding results in high-quality parts comparable to injection-molded components. This makes vacuum casted models especially suitable for fit and function testing, marketing purposes or a series of final parts in limited quantities. Vacuum Casting also lends itself well to a variety of finishing degrees, and we can match the finish you need for your parts.

Vacuum Casting Video | DDPROTOTYPE

Advantage of DDPROTOTYPE

1 Material selection

We offer rigid and flexible polyurethane casting materials ranging from very soft and flexible (Shore A) to extremely strong and impact resistant (Shore D). The casting color of the parts is strictly customized according to your requirements.

2 Scalability

Our polyurethane casting service is suitable for small batch production in quantities of one to hundreds. Generally speaking, the silica gel mould can accurately cast about 20 parts. The maximum number varies from part design to material casting.

3 Color Matching and Completion

Vacuum casting service can reproduce small details. It is almost unnecessary to finish because the required texture and finish levels are precise copies of the master molding.

4 Fast turnover

Vacuum casting service can be delivered within 10 days as soon as possible, depending on the size and quantity of parts. In general, injection moulding may take several months to complete.

5 Affordability

Vacuum casting service is cheaper than injection moulds, resulting in lower prices. Moreover, in China, labor costs are relatively low and resources are abundant. The cost of the same parts is 30% to 50% lower than that in Europe or the United States.

6 Produce large parts

Vacuum casting can produce very large parts, which can remove bubbles and enable materials to capture details. Almost unlimited complexity is allowed, including sharp inner corners that CNC machining cannot achieve, and designs where injection moulding cannot achieve uniform wall thickness..

Available polyurethane materials

Flexible Urethane (Shore D 62-67)

Rigid Urethane (Shore D 82-86)

Rigid Urethane (Shore D 62-67)

Polyurethane materials are imported from Japan or France, ABS-Like, PMMS-Like, Opaque Elastomer, Waterclear Elastomer, If you have the hardness material you need, please tell us, we will accommodate it.

Standard

The surface treatment of the parts has a high finish, and the color can be painted accurately according to your designation.

Customized

DDPROTOTYPE can certainly provide additional processing, including custom texture and assembly, to meet your needs.

General Tolerance

Each inch is between (+0.010 inches) and (+0.003 inches), whichever is larger. Irregular or overly thick geometric structures may be deviated or deflected by shrinkage.Due to the thermal expansion of liquid and the characteristics of flexible die, the shrinkage rate is estimated to be + 0.15%.

We recommend a minimum wall thickness of 0.040 inches. (1 mm). However, in some cases, the thinner wall thickness will be reduced to 0.020 inches. (0.5 mm) can be used for small parts. Usually, the larger the component, the larger the wall to ensure proper support.

Vacuum Casting Process:

1 Main mode: The main pattern for manufacturing final parts. 3D printing or CNC machining is most commonly used because of its high resolution and naturally smooth printing surface.Patterns need to withstand a temperature of 40 degrees.

2 Forming: wrap the main pattern in liquid silicone to form an accurate mould. When the mould solidifies, it is cut into two different halves and the main pattern is removed.

3 Pouring: pouring liquid plastics into the silicone mould and then putting the mould into the vacuum chamber will help remove bubbles in the liquid material. Once cured, half of the silicone resin is separated and the newly formed part is removed. Repeat this process until the required quantity is reached.

Vacuum Casting Application

1 Low-volume manufacturing

Polyurethane castings are well suited for low-volume manufacturing – less equivalent to support investment in injection moulds – and for first-time production parts, which can be completed months before injection moulding is ready.

2 Advanced Prototype

Vacuum casting technology and relatively inexpensive tools make it easy and economical to make any necessary design changes. In addition, different polyurethane materials can be used together with the same patterns, so that various materials can be used to test whether the design is appropriate.

3 Market testing

End-user functions and high-quality surface treatment make vacuum casting parts an ideal choice for consumer testing, user evaluation and conceptual models. The use of vacuum casting technology means rapid market testing.

Polyurethane Vacuum Casting Case

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3D Printing

Martin.mu — Fri, 07 Jun 2024 14:59:36 +0000

DDPROTOTYPE is a leading provider of online 3D printing services. Whether you need prototypes or parts, we can produce them for you as quickly as possible. We provide you with one-stop service of high quality customized 3D printing parts at low cost.We use the latest incremental manufacturing process to produce functional prototypes and parts at reasonable prices in more than 60 metals and plastics. Whether it’s metal printing or plastic printing, we can all accept the challenge.

Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS) is a powerful 3D printing technology, which can generate high precision and durable prototype parts, which can be directly used for final use and suitable for low-volume production or rapid prototyping.

Additional Manufacturing Layer (SLS) technology involves the use of high power lasers (e.g., carbon dioxide lasers) to melt small particles of plastic powder into blocks with the desired three-dimensional shape. Lasers selectively melt powder materials by scanning cross sections generated by 3-D digital descriptions of components on the surface of the powder bed (e.g. from CAD files or scanning data). After scanning each cross section, the powder bed is reduced to a certain thickness, a new material layer is applied to the top, and the process is repeated until the component is completed.

3D Printing Video | DDPROTOTYPE

Stenography (SLA)

Stereolithography (SLA) is one of the powerful 3D printing technologies. It can generate extremely accurate and high resolution parts, which can be directly used for final use and suitable for small batch production or rapid prototyping.

SLA is an add-on manufacturing process that provides higher resolution printing than many other 3D printing technologies, allowing customers to print parts with fine details and surface treatment. SLA is used to make customized parts in prototype and production environments; it is usually used as an alternative to plastic parts for injection moulding.

Fused Deposition Modeling (FDM)

Fused Deposition Molding (FDM) is a 3D printing technology widely known for its high speed, high precision and competitive price. The machine accurately extrudes melted plastic filaments to form parts. Parts are very hard, especially compared with selective laser sintering (SLS), which makes them very suitable for projects with rigid requirements.

Direct Metal Laser Sintering (DMLS)

Direct metal laser sintering (DMLS) is a three-dimensional metal printing technology, which uses laser to construct prototypes from CAD files and produce metal parts to selectively fuse fine metal powders into stainless steel or aluminium materials. DMLS machines can use metal materials to produce highly complex features and integrated components, which are difficult to achieve through subtraction manufacturing technology.

Advantages and Benefits of DDPRTOTYPE’s 3D Printing

In rapid prototyping and low-cost prototyping, no other process can compare with 3D printing. If you need a beautiful part to test the shape of 3D rapid prototyping is the right choice. Complex geometry can be achieved by 3D printing so that you can accurately assess prototype manufacturability and other considerations. Advantages include:

low cost

Costs without machining tools
Minimum settings involved
For the materials used – no waste

Fast turnover

Parts can usually be shipped within two days.
Simple Procedure for Making 3D Prototype
Fast turnaround accelerates iterative testing

Material selection

Increasing range of material selection
ABS, PC, nylon, metal and other materials
SLA, SLS, FDM, DMLS for wider material selection

Complex shape

Suitable for any geometric shape
Create according to your requirements
No additional cost required

Scalability

Quickly produce most of the same products
Improving product quality
Excellent impact strength

High precision

Tolerances of +/-0.005 “or +/-0.002” per inch
The surface of the part is smooth, and no secondary processing is needed.

What industries does 3D printing apply to?

The accuracy and versatility of 3D printing make it an ideal choice for many applications and industries. Anything that requires complex forms and strict specifications is perfect for 3D printing. For example: medical, dental, aerospace defense, electronic products, automobiles.

Finishing and Parts Manufacturing

Whether you need custom finishes, material quality or other services, we can meet your needs and even exceed your expectations.
-Material: More and more material choices, more than 60 kinds. New advanced materials can be used to simulate the properties, appearance and sensation of various resins, including ABS, nylon, PC, etc.
-Finishing Service: Once the production is completed, we can deliver the parts to you; or we can provide customized finish, including spray painting, offset printing, screen printing and laser etching. Let us know how you envision your finished product, and we will work with you to make it a reality.

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EDM Machining

Martin.mu — Thu, 06 Jun 2024 23:05:01 +0000

As a leading prototype manufacturer in China,DDPROTOTYPE could provide customers with precise EDM Machining services. EDM is mainly used for machining parts with complex shapes of dies and holes and cavities; machining various hard and brittle materials, such as carbide and quenched steel; deep holes, special holes, deep grooves, narrow slices; forming tools, samples and processing various screw ring gauge tools and gauges. We adopt advanced Japanese production equipment and processing technology to produce high-quality products. The products are mainly sold to Germany, the United States, Japan, Italy, Singapore, Thailand, Malaysia and other countries and regions. We can manufacture, process and inspect according to the world brand standard. It can be manufactured according to GB, JIS, DIN, AISI and other international industry standards.

What is EDM Machining?

The core of EDM is two electrodes (one is workpiece), which are separated by dielectric liquid, usually deionized water or oil. When the electric field between the two electrodes is high enough, the dielectric breaks down, the current flows through, and the material is removed from the two electrodes. The current between the electrodes is not constant; instead, the instantaneous debris is washed away by the fluid. This can be repeated to erode features of fine control that cannot be created by traditional processing methods.

Advanced EDM Machining Equipments

In 2014,We purchase Mitsubishi -MV2400 from Japan.EDM accuracy: dimension tolerance (+0.001 mm), coaxiality less than 0.002, true roundness 0.0015 mm, surface roughness Ra0.025, straightness 300 mm less than 0.002. In 2014, we purchased 4 sets Fanuc EDM equipments from Japan. The discharge precision can reach 0.005mm, the discharge clearance angle is the smallest R0.015, and the mirror discharge finish can reach Ra0.2.

EDM Machining Video | DDPROTOTYPE

Mitsubishi -EA12V Specifications

                             Travel (X / Y / Z) in mm                                                                                                               400 / 300 / 300
                             Max. workpiece dimensions (W x D x H) in mm                                                          850 x 640 x 250
                             Max. workpiece weight in kg                                                                                     700
                             Max. electrode weight in kg   50                                                                                            50
                            Table dimensions (W x D) in mm                                                                                             700 x 500
                            Daylight (table – C-axis with EROWA chuck) in mm                                                              152,5–452,5
                            Max. dielectric filling level                                                                                                         300
                            Overall dimensions with tool changer (W x D x H) in mm                                                    2145 x 2050 x 2380
                            Machine weight in kg                                                                                                                 3725
                            Mains voltage   3-phase                                                                                                            400 V/AC, 50/60 Hz

Advantages of EDM

1 It is a complementary processing method for traditional manufacturing processes such as Swiss CNC turning and milling. It is very suitable for the production of high precision gears, mechanical components and rapid turning prototypes with complex geometry.
2 Create complex shapes, otherwise it is difficult to produce with traditional cutting tools.
3 Cut extremely hard, challenging and special materials into very precise tolerances for high-precision mechanical components.
4 For very small workpieces, traditional cutting tools may damage parts due to excessive cutting tool pressure.
5 There is no direct contact between tools and artifacts. Therefore, fine parts and weak materials can be processed without any deformation.
6 No burrs.
7 After the process is completed, little or no polishing is required.

Engineering superiority

In the processing of precision parts, the popularity of EDM machining is increasing. It has proved to be a complement to traditional manufacturing processes such as SWISS turning and milling. It is very suitable for the production of geometrically complex high-precision gears, mechanical parts and rapid turning prototypes.

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Finishing service

Martin.mu — Thu, 06 Jun 2024 21:13:33 +0000

In addition to high precision prototype machining technology, DDPROTOTYPE also has rich experience in finishing service. With the support of our internal laboratories or partner suppliers, we can complete various finishing services to meet your visual or functional requirements.
Finishing service is a process used to change the prototype surface to give it a unique or desired appearance or function. Different technologies are used to improve appearance, adhesion, weldability, corrosion resistance, hardness, conductivity and other properties. Regardless of the processing method, DDPROTOTYPE can provide high quality finishing service for your prototype. We have some skilled experts to complete the task, so your prototype machining quality is very high. If you want perfect prototype machining, please contact us for quotation.

Anodizing

Anodizing is the formation of an oxide film on the surface by electrolysis using metal or alloy prototype as the anode. It makes the prototype surface colored, has better corrosion resistance, wear resistance, hardness to protect the prototype surface.anodizing is an ideal surface treatment for paint and primer. It also looks great.We usually use type II anodizing, which allows us to add tones or dyes to your parts for various visual effects. Type III anodic oxidation is also suitable for prototypes requiring particularly hard surfaces.

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Electroplating (plating)

The principle of electrolysis is to coat the product layer with a thin layer of another metal or alloy. Electroplating products can prevent metal oxidation (such as rusting), improve wear resistance, conductivity, reflectivity, corrosion resistance (such as copper sulfate), and improve the beautiful appearance.
Galvanizing (coloured zinc, white zinc, blue-white zinc)
Copper plating (brass, spare copper, copper sulfate)
Electroless nickel plating (mist nickel, Pearl nickel, bright nickel, black nickel)
Chromium plating (decorative chromium and hard chromium)
Gold plating (genuine gold, imitation gold)
Silver plating

Grinding and Polishing

We attach great importance to providing the most professional finishing services for your prototype and production needs. This usually involves hand-polishing to prepare parts for subsequent painting and plating.
Grinding is used not only to prepare for painting, but also to make the final surface treatment. We can provide various metal effects for drawing and satin surfaces, as well as optical transparent polishes on transparent acrylic resins. All our work is done in a clean, well-lit, environmentally friendly model workshop.

Optical prototype finishing service

In the prototype manufacturing of optical transparent components for camera components and automotive lamps, it is important to use manual polishing technology to implement transparent products to meet customer needs. Engineers face each part and perform surface treatment according to the different shapes and transparent specifications of each part. DDPROTOTYPE transparent resin material surface polishing technology reliability has been highly valued and trusted by customers.

Powder Coating

DDPROTOTYPE provides powder coating services for your prototype, covering various steel and aluminum prototypes, etc. This means that you can provide durable, corrosion-resistant solutions for your metal prototype. The benefits of powder coatings include chemical resistance, ultraviolet shock resistance and electrical insulation. These advantages make powder coatings an ideal choice for industries where “wear” often occurs, such as freight and transportation industries.

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Wire Cutting EDM

Martin.mu — Thu, 06 Jun 2024 19:22:47 +0000

DDPROTOTYPE provides first-class Wire EDM machining services, which can produce precision parts with tolerances within (+0.005 mm) of your design size. With the most advanced line EDM equipment and advanced programming, we can produce the most complex parts with perfect accuracy and repeatability, whether you need rapid prototyping, low volume manufacturing or thousands of mass production.

Our Wire EDM capability

Our expertise and advanced production equipment enable us to produce high-quality, low-cost precision parts and components from almost any type of conductive material. Whether you are looking for wire cutting or drilling, our CNC automation system ensures that the dimensional accuracy is within (+0.0001 inches) and that it is perfectly repeatable.

We purchased Mitsubishi MV-2400 from Japan designed for WEDM products ranging from simple mechanical parts to complex high precision geometries (such as injection moulds and tools). MV-2400 has high efficiency servo amplifier and linear axis motor (LSM), which can reduce energy consumption without loss of power.

Wire EDM Machining Video | DDPROTOTYPE

Mitsubishi MV-2400 Specification/function

                                Machine Travels: X x Y x Z in (mm)                                                         23.6 x 15.7 x 12.2 (600 x 400 x 310)
                                                    Maximum Workpiece Dimensions: W x D x H in (mm)                               41.3 x 32.3 x 12.0 (1050 x 820 x 305)
                                                    Table Dimensions: in (mm)                                                                            33.0 x 25.2 (840 x 640)
                                                    U/V Travels (from center): in (mm)                                                      ±3.0 x ±3.0 (±75 x ±75)
                                                    Taper Angle @ Thickness: in (mm)                                                       15 deg.@ 10.2 (15 deg.@ 260)
                                                    Wide Angle Taper (Optional Guides Required)                                  45 deg. @ 2.4″ 60mm (No AT Possible)
                                                     Minimum Drive Unit / Resolution                                                        0.000002 / 2 µin ( 0.00005 / 50nm)
                                                     User Program Storage [Hard Disk Size]                                                  1 GB [32 GB CFAST Card Size]
                                                     Wire Diameter Possible: in (mm)                                                        0.004~0.012 (0.1~0.3)
                                                     Minimum Start Hole Diameter: in (mm)                                                           0.02 (0.5)

For Complex Parts Machining

We focus on creating complex parts with unique geometry and strict tolerances for various industries and applications. Skilled internal tool manufacturers and system programmers, as well as our most advanced EDM equipment, can help us to provide high-quality, high-precision parts and components. These components are too complex to be manufactured by traditional processing methods.

Advantages of WEDM

EDM machines have a wide range of advantages that other manufacturing methods can not match. Some reasons for choosing Wire EDM Machine include:

1 Shorten Delivery Time: Because the EDM process is very precise, it can be set correctly at the first attempt to greatly shorten delivery time. It reduces the time required to market the product from the prototype stage.

2 Complexity: Wire EDM is an excellent choice for manufacturing sophisticated and complex parts. With Wire EDM, the same complex parts can be manufactured again and again with the same accuracy.

3 Taper: EDM can be used to cut long taper that other processing methods can not produce.

4 Less setup time: EDM manufacturing reduces the need for dies, thereby reducing installation time.

5 Accuracy: EDM manufacturing is your best choice when you need highly accurate processing. It is capable of cutting to match your design to within ± 0.0001 inch.

6 Accurate internal incision: It is difficult to produce square edge internal incision by other processing methods, but Wire EDM can achieve it.

7 Better results: EDM can produce parts without burrs or tools. Wire EDM also produces better surface finish than other manufacturing forms.

8 Fine hole drilling: EDM drilling can produce small holes that are difficult to produce by other methods.

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Quality Inspection

Martin.mu — Thu, 06 Jun 2024 16:32:53 +0000

DDPrototype has invested a lot of money in the inspection department to ensure that the quality meets the customer’s requirements accurately. It has introduced a series of advanced testing equipment, including Heixconn CMM, PolyMax gun, XRF analyzer, Smart Scope Zip Lite 300, height caliper, micrometer, PL and so on. UG gauge and so on, the measurement accuracy can reach (+0.02 um). Our quality assurance system includes the implementation of quality inspection in every process. Experienced inspectors can use reliable and comprehensive inspection means and standards. DDPrototype products continue to meet the growing needs of customers. Because we know that we are in a very strict and serious industry, and that a small mistake can affect the delay of a great innovation project.

Quality Report

We also offer quality reports to accompany products, which diagnoses critical dimensions, angles, finishes, etc after a prototype is completed and that it conforms to the specifications.This is ideal for ongoing tracking and monitoring of mass production components, data management, and may also assist with long-term cost-reduction strategy. Ultimately, it places confidence in your hands and downstream within the supply chain.

Depending on your requirements, a quality report can be generated for any quantity of parts.

Quality Inspection and Testing

High quality products need strict management control and advanced equipment. DDprototype, in order to ensure product quality, we insist that each project must follow the following steps:
1. Check 2D and 3D to ensure the corresponding drawings. The technical team provides free design, programming suggestions and revisions.
2. Audit purchase material orders to ensure that drawings meet customer requirements.
3. Inspection and testing of feeding materials
4.Complete process testing, including the first finished product inspection, machining inspection, runs through every process of processing.
5.Complete or sample output inspection and written inspection report.

Quality Inspection Video | DDPROTOTYPE

Environmental protection measures

In prototype manufacturing, industrial waste as an environmental burden is discharged, especially in the processing and surface treatment stages, such as cutting, casting and sheet metal processing. Controlling these emissions and reducing the environmental burden are the main problems. It is also necessary to save energy and reduce costs by reducing energy losses, not only to meet national environmental standards, but also to meet international standards. We have been committed to environmental improvement, reducing the environmental burden by reducing industrial waste and promoting recycling.

ISO Certification

We are honored to have the certification and compliance of ISO 9001:2015 and ISO 13485:2016. This shows that we are committed to continuous quality improvement and contribute our due strength to the world’s manufacturing industry. We are proud that our long-term guarantee has won the recognition and respect of our customers.

Internal inspection equipment

To get high quality prototypes and parts for customers, it needs a combination of good process control technology and advanced equipment. At DDPROTOTYPE, we have invested heavily in internal inspection, measurement and testing equipment, and tested all materials. We carry out plastic and metal testing and provide material identification (PMI) of all incoming materials, so you are fully confident to receive the products you ordered.

Coordinate Measuring Machine

We spent a lot of money on the acquisition of Hexagon CMM, which not only plays an important role in precision detection and product quality control, but also plays an increasingly important role in design, production process control and die manufacturing. The measuring machine products provided by Hexagon are widely used in automotive industry, aerospace, machine tools, national defense, military industry, electronics and moulds with an accuracy of 0.001 mm.

PolyMax Gun

In order to make sure that the resin we use is suitable for injection moulding parts, we invested in PolyMax analysis guns. The device uses a laser beam to test the surface of the resin sample and reads the unique characteristics emitted by its molecular vibration. According to the database of hundreds of plastic types in memory, the resin samples can be checked whether they meet the customer’s requirements. In this regard, we have always been in the lead, each time to provide you with appropriate materials.

XRF analyzer

X-ray fluorescence (XRF) analysis emits short-wave X-rays or gamma rays from equipment to metal, plastics, ceramics and other materials. By comparing the reflected wavelengths, elements and relative concentrations in materials can be detected. This process is a non-destructive process and will not affect materials.

SmartScope ZIP Lite 600

SmartScope ZIP Lite 600 is a non-contact optical measurement system, which uses high-intensity white LED lamp to measure components quickly and accurately in two dimensions. Precision mechanical motor platform provides sufficient measurement accuracy and stability in granite base and measurement axis. Keep the image coaxial and clear throughout the zoom range.

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Company Profile

Martin.mu — Thu, 06 Jun 2024 11:08:42 +0000

DDPROTOTYPE is an ISO9001-2015 certified prototype manufacturer with a dedicated team and the latest technology and equipment to ensure the successful operation of your project. Whether you need to use 3D visualization to manufacture complex prototype parts, or want to display the final stage of the product in the top-level meeting, DDPROTOTYPE could meet your needs.

What does DDPROTOTYPE do?

DDPROTOTYPE is committed to providing high-quality rapid prototyping and small batch manufacturing services, including CNC machining, vacuum casting, 3D printing, rapid tooling and plastic injection molding, sheet metal prototyping, plastic and aluminum extrusion. We provide high quality manufacturing solutions that can complete your design in hours. This gives you the opportunity to conduct rigorous product testing and make all necessary changes to refine the design before full production. One stop prototyping services, from visual design models to fully functional prototypes, are made of more than 150 engineering grade plastics and metals, with strict tolerances and fast turnaround times.

What do you expect from DDPROTOTYPE?

DDPROTOTYPE is headquartered in Shenzhen, China. With the expansion of its business, it moved from Hong Kong, which was originally incorporated, to Shenzhen. DDPROTOTYPE is one of the most professional manufacturers of prototype machining and low volume manufacturing in China. With innovative services and highly skills, it maintains a competitive advantage in the labor force. Our goal is to provide high quality prototypes and customized low volume manufacturing with reasonable price for production intention. Our business is based on providing cost-effective solutions that benefit our customers at all stages of product development. Our largest asset is our customer base, which is growing rapidly through the word-of-mouth of our global customers, ranging from independent inventors or designers to large industrial, commercial, medical, automotive and even aerospace companies.

Your Custom Prototype Manufacturing Service Expert

DDPROTOTYPE has high-precision imported machine tools of 3-axis, 4-axis and 5-axis from Japan and USA, which enables us to achieve strict tolerance. We have also invested in material testers so that we can verify the materials used and make sure they are the right materials for each project. And we can get the measurement results quickly from our CMM.

Why Choose DDPROTOTYPE?

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