TIPS WITH TONY: Machining Versus Molding for Magnesium Parts

In our latest tip, we’re talking about magnesium, and how to use it in product design for metal parts that need to be lightweight yet strong.

Magnesium works well for reducing component weight in place of steel or aluminum as it’s the lightest structural metal currently available. This lends itself well to a range of applications in the automotive, aerospace and electronics industries.

It’s heavily used in vehicle lightweighting to lower fuel consumption, reducing automakers overall carbon footprint. It’s also used to create lighter and thinner electronics or simply whenever a lightweight yet strong backbone material is needed in a part. Be sure to test and review magnesium’s material properties closely as it’s not always the proper substitute for other metal or plastic materials.

Magnesium versus

Steel

Aluminum

Plastic

75% lighter

33% lighter

Greater stiffness

Thinner walls

Similar or greater mechanical properties

Improved strength and wear resistance

Consolidation of parts

Consolidation of parts

Higher temperature

Machines faster

Machines faster

Creep resistant

Reduced tooling costs

Improved corrosion resistance

Fewer supports needed

What manufacturing methods are there for magnesium? Proto Labs offers both CNC machining and injection molding for prototype and low-volume mag parts, though magnesium die casting also used in the industry.

How do I choose the right manufacturing method? Quantity, lead time, size and material properties will greatly impact which manufacturing method to use.

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Sportech Uses Quick-Turn Machining for Design Validation

From frozen trails to rugged desert valleys and muddy creeks, power-sports vehicle drivers put their machines to the test. Producing custom parts for many of those snowmobiles, utility vehicles and motorcycles — on short production cycles and with manufacturers gearing up for large-scale production — is another sort of test for Minnesota-based Sportech, Inc.

Sportech prototyped durable nylon clips and hooks with CNC machining.

Sportech is a product development partner to seven of the eight largest power-sports vehicle makers. The company specializes in full-service design, development and production of custom parts and accessories, going from concept or rough sketches to 3D CAD modeling and rapid prototyping. Its services include thermoforming, drape forming, CNC routing and integrated assembly. Products include windshields, body panels and screen-printed parts for motorcycles, snowmobiles, all-terrain vehicles (ATVs) and utility vehicles (UTVs).

While Sportech has grown into a leading product developer for original equipment manufacturers, what hasn’t changed since the company’s early days is the challenge of meeting tight product development deadlines.

In our latest case study, read how Sportech used quick-turn CNC machining at Proto Labs to validate the design of components before shifting to large-scale production.

How Digital Manufacturing is Changing the Industry Forever

Our current issue of the Proto Labs Journal looks at the convergence of complex software and automated hardware bringing rise to the digital age of manufacturing. Follow the thread of a 3D CAD model from upload to digital analysis to final part, and the massive compute cluster that’s powering it all.

Along with our cover story, read about leveraging low-volume injection molding, the latest in innovative technology we’ve mined from the Internet  and new service offerings at Proto Labs.

Read the full Journal now.

1 Million Machining Quotes

Sound the noisemakers and release the confetti! We’ve just quoted our 1 millionth machining order in North America. While legal won’t let us give out an oversized check or free parts for life to whoever put us over a million, it’s another great reminder that designers and engineers are using quick-turn CNC machining more than ever for prototypes and production parts. We launched our machining service in 2007 and have continued to enhance our capabilities with new plastic and metal materials and processes like lathe.

So, how do these numbers relate to our other services? We’ve quoted more than 700,000 injection molding orders and 525,000 3D printing orders, putting Proto Labs well over the 2 million mark in North America.

And for that, we sincerely thank our customers.

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The Reviews Are In!

We recently published a comprehensive, 72-page “Digital Manufacturing for Dummies” book that covers the benefits of using additive manufacturing (3D printing), CNC machining and injection molding for custom prototyping and low-volume production.

Well, a few editors of industry publications have had a chance to read and review the book. Here’s what they’re saying:

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