Prototype to production - validate before you commit to tooling.
When you move to HPDC production, there are no surprises.
Committing to high-pressure die casting tooling before a component is fully validated is one of the costliest mistakes in product development. Tooling modifications after the first article are expensive, time-consuming and - in many cases - avoidable entirely.
Alucast offers sand cast aluminium prototypes engineered from the outset to be geometrically compatible with our HPDC processes. You validate the component - its geometry, dimensions, performance and manufacturability - in sand casting first.
HPDC-Compatible Prototypes
Designed so your component transitions cleanly to high-pressure production without redesign.
Same Team, Same Site
The engineers who cast your prototype take it to production - no knowledge gaps between development and manufacture.
Magmasoft at Prototype Stage
We model fill and solidification before your first prototype is poured, eliminating the most common design issues.
Fast Turnaround
Prototype sand castings are significantly faster to tool than die casting - physical parts in your hands earlier.
In-House CNC Machining
Prototype blanks machined to finished dimensions in-house - a fully functional component, not just a raw casting.
NDT Available
Dye-penetrant testing on prototype components for early integrity validation.
Design review and casting simulation
Sand casting prototype manufacture
In-house CNC machining to finished dimensions
First article inspection and customer sign-off
Tooling investment for HPDC production
Volume production with validated, proven geometry
This pathway reduces technical risk at every stage - and keeps the entire process under one roof.
- 01Engineering teams developing new aluminium components for automotive, industrial, hydraulic or aerospace applications
- 02Procurement teams who need a physical first article before approving production tooling investment
- 03Any buyer switching from an existing casting supplier who needs to revalidate a component before moving production
Prototyping Guide
The full prototype-to-production pathway, in a single reference document.
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