How does Neway ensure urethane prototypes transition smoothly into mass production processes?

Design for Manufacturability (DFM) Integration

The most critical step for a smooth transition begins during the prototyping phase. Our engineers conduct a comprehensive Design for Manufacturability (DFM) analysis on your urethane prototype. We identify and address potential production issues related to wall thickness, draft angles, fillet radii, and undercuts that are easily achieved in Urethane Casting but problematic in high-pressure Metal Casting. This proactive approach ensures the part is designed for efficient die casting and Post Machining from the outset.

Material and Process Selection

While urethane prototypes perfectly mimic the form and fit of a final part, they cannot replicate the material properties of metal. Neway guides the selection of the optimal production material, whether it's a high-strength Die Cast Aluminum Alloy like A380, a precision-suited Die Cast Zinc Alloy like Zamak 3, or a highly conductive Copper Brass Alloy. This selection is validated against the prototype to ensure performance requirements are met in the mass-produced component.

Prototype-to-Tooling Bridge

Urethane prototypes are invaluable for creating the master patterns used in Tool And Die manufacturing. The physical prototype allows our toolmakers to verify mold flow simulations, design effective gating and venting systems, and anticipate cooling stresses. For complex parts, we may employ CNC Machining or 3D Printing to create mold inserts directly from the approved prototype data, drastically reducing tooling lead time.

Pilot Production and Validation

Before committing to full-scale Mass Production, we leverage our Low Volume Manufacturing capabilities. Using the initial production tooling, we manufacture a small batch of die-cast parts. These are directly compared to the original urethane prototype for dimensional accuracy and functionally tested. This step confirms that the tooling produces parts that meet all design and functional specifications.

Seamless Post-Processing Integration

A key advantage of Neway's One-Stop Service is the seamless integration of secondary operations. The finishing requirements validated on the urethane prototype—such as Powder Coating, Anodizing, or Assembling—are directly translated into established, scalable processes for the mass-production run, ensuring a consistent final appearance and function.