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Intake manifold (VR6-4 V)
Although suction modules in series production can now be manufactured from fibreglass reinforced plastics, manufacturers prefer to make the first prototypes from aluminium: The dimensional stability of aluminium parts allows the developers to draw conclusions about the series parts' characteristics expected even in the prototype stage.
To make prototypes quickly and without the modelling equipment that is usually necessary, the ACTech GmbH also developed Rapid Prototyping technologies appropriate for large and thin-walled castings. Outer mold segments or cores up to a dimension of 2.5 meter are made by DMM-Direct Mold Milling®. In this way it is possible to build up sand casting molds for extremely large-sized castings in combination with Direct Croning®-cores for filigree contours quickly and at low cost. Making small part quantities in the early stages of a new engineering project, the developers may investigate alternative design variants almost simultaneously. Stages of development may be implemented into prototypes quickly and at low cost regardless of the available modelling equipment and its limitations.
The DMM®-segments may be replaced by the modelling equipment for subsequent small series manufacturing with higher part quantities.
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