Rapid Prototyping Service for Precise Metal Casting Parts
Speed, precision, and flexibility are critical in developing custom metal parts. At Neway, our rapid prototyping service bridges the gap between concept and production by providing high-fidelity prototypes that accurately reflect the final cast components. Integrating metal casting expertise with advanced prototyping technologies empowers engineers and product developers to validate designs, accelerate iterations, and reduce time-to-market.
Our rapid prototyping solutions support various alloy types and casting processes, including aluminum die casting, zinc die casting, and copper alloy casting. Neway delivers reliable, cost-effective results if you require mechanical test samples, functional validation, or pre-production tooling trials.
Why Rapid Prototyping Matters in Metal Casting
Prototyping is no longer optional in modern product development—it is essential for reducing design risks, validating manufacturability, and accelerating time-to-market. For cast parts, prototyping offers several strategic benefits:
Detects design flaws before full tooling investment
Enables early functional and mechanical testing
Supports pilot production and market feasibility studies
Facilitates faster communication between design, engineering, and manufacturing teams
At Neway, we ensure that prototypes reflect production-level accuracy to ensure a smooth transition to full-scale casting.
Prototyping Methods for Metal Casting Projects
Our prototyping service incorporates both digital and physical technologies to accommodate different stages of development and material needs.
1. 3D Printing (Additive Manufacturing)
Through 3D printing, we provide fast-turnaround parts for initial design validation. We offer:
SLA (Stereolithography) for high-detail visual models
SLS (Selective Laser Sintering) and DMLS (Direct Metal Laser Sintering) for structural and functional prototypes
Accuracy down to ±0.1 mm and complex geometries with undercuts and internal channels
3D printed parts are especially valuable for quick iterations and design visualization.
2. Urethane Casting
Our urethane casting service is ideal for short-run plastic or elastomer-like parts production using silicone molds. This process is suitable for:
Simulating cast plastic parts
Creating housings, seals, and flexible fixtures
Producing up to 50–100 units with minimal tooling cost
It serves as an excellent intermediary between concept modeling and hard tooling.
3. Soft Tooling and Bridge Molds
We use soft tooling or rapid mold inserts for high-fidelity prototypes made from actual casting alloys (e.g., aluminum, zinc, copper). These are fabricated using high-speed CNC or low-volume tool and die making methods. Advantages include:
Realistic cast surface finishes and tolerances
Alloy-specific behavior, including shrinkage and porosity analysis
Feasibility testing of gating, venting, and thermal design
This approach is ideal for pilot testing or low-volume production before hard tool commitment.
Compatible Casting Materials for Prototypes
Our rapid prototyping service covers a wide range of casting materials, including:
Aluminum Alloys: A380, A356, AlSi12 for lightweight, high-strength applications
Zinc Alloys: Zamak 3, Zamak 5, ZA-8 for tight-tolerance, high-volume readiness
Copper Alloys: Brass 360, CuZn40, CuNi10Fe1 for thermal and electrical performance
We also support plastic prototype equivalents for testing form, fit, and function before transitioning to metal.
Integrated Workflow from Prototype to Production
Neway’s end-to-end service model ensures consistency between your prototype and the final production part. We offer:
Design for Manufacturability (DFM) support and CAD optimization
Engineering consultation to align prototype objectives with final casting requirements
Quick lead times (as fast as 3–7 days, depending onthe method)
Seamless transition to low volume manufacturing or mass production
Before approval, all prototype parts undergo dimensional verification, surface quality inspection, and functional review.
Industries Served
Neway’s rapid prototyping service is trusted by clients in:
Automotive: Engine covers, brackets, and lightweight transmission housings
Aerospace: Heat sinks, sensor mounts, and structural frames
Medical Devices: Instrument enclosures, ergonomic grips, precision mounts
Industrial Equipment: Hydraulic blocks, connector housings, heat shields
From single proof-of-concept units to small production runs, our prototyping capability supports fast, accurate, and production-intent development.
Start Prototyping with Confidence
With advanced tools, proven casting knowledge, and a deep understanding of material behaviors, Neway is your one-stop partner for prototyping cast metal parts. Our rapid prototyping service ensures you minimize risk, compress development time, and move confidently toward full-scale manufacturing.
Contact us today for a quote or request a design review for your next project.
Frequently Asked Questions
What’s the difference between rapid prototyping and bridge tooling?
How many units can you produce using soft tooling or urethane casting?
Are design modifications possible during the prototyping phase?
