The customer demanded an elongation of more than 8% for the use of components in crash tests. Properties like these cannot be achieved in rapid prototyping investment casting with the requested materials . So it was decided to substitute the original die casting alloy with an aluminium alloy that can be heat-treated. Furthermore, a special casting system was used in combination with animmediate cooling of the castings. In this way, ACTech was able to create the optimum basic structure for the follow-up part hardening (T64) with customized technology. The tests on the customer's test bench confirmed the desired variables.
The prototypes were made by rapid prototyping investment casting based on a silicone mold and wax models made of it. This enabled the precise reproduction of the thin-walled and ribbed contour in both parts. Because of their highly accurate fit, the prototypes are usable as well as the later die castings, without additional machining.
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